G/• NI• --7 Indiana Air

Permit

Compliance lestlng

General Shale

Brick,

Inc. Mooresville, Indiana Report on: Sttlilt r Dioxide Oxide.•_ H.l,drogen Chloride/H.rdroL, ett Flottride Particulate Matter

<10

Performed by: :\Air Analysis,

Inc. Project Number:

447 January 24, 2007

AAir Analysis,

Inc. 3904Clarks Creek Road • Plainfield,

Indiana

46168 317.837.8514 877.683.TESTAnalysis, Inc. General

Shale Brick, Inc. Project Number:

447 DESCRIPTION OF SOURCE

PROCESSES

AND FIEI,D NOTES' One (1) brick manufacturing

lines, identified

as EU-002,

consisting

of the following:
One (1) brick manufacturing

line, identified

as Line 2, installed

in 1987, located at Plant No. 32, equipped

with consisting

of the following:

* One (1) tunnel pre-dryer

and one (1) tunnel dryer using waste heat from Line 2 Kiln, and one (1) coal and natural gas-fired

kiln, identified

as Line 2 Kiln, equipped with a dry lime injection

baghouse,

identified

as DIFF-02,

exhausting

to Stack DIFF-02,

rated at 25 million British thermal units per hour, capacity:

13.7 tons of bricks per hour. Pursuant

to 40 CFR 63, Subpart

JJJJJ, this is an existing affected source using an emissions

control system to comply with the rule.
• (B) One (1) mill room, identified

as EU-P32-MR,

equipped

with a baghouse, identified as CD-P32-MR,

capacity:

70 tons per hour.

Actual recorded

production

material

information

is in Appendix.:i_kAir Analysis,

Inc. General

Shale Brick, Inc. Project Number:

447

APPEND• Ii

FIELD DATA

PRINTOUTSSOURCE TESTED:

Kih• 32 COMPANY NAME: Gel•e•a! Sha!• Brick DATE OF TEST: 01/24/07 Pollutant Emissions HCL Ibs/hr HF Ibs/hr SO2 ppm SO2 Ibs/hr "Nox ppm NOx Ibs/htr Run 1 0.0577 0.3402 79.8500 17.2850 51.6700 8.0450

Run 2 0.0673 0.4900 60.2000 12.8775 55.8400 8.5917

Run 3 0.0640 0.5345 66.6900 14.5911 53.1400 8.3627 Average 0.063O 0.4549 68.9133 14.9179 53.5500 8.3331 A•g.S•ckVoI. Flow Ra• ACFM

21,733.72

21,477.19

21,966.82

21,725.91 DSCFM •,vg. Stack Temp. 'Stack Gas Velocity Avg. Velocity Head Avg. Sq. Rt of Delta P

%lsokinetics; •,llowable isokinetic

90-110% •/o Moisture

of Stack Gas Sample Volume 236.100

238.526

240.300

238.309 51.585 51.604

52.833

52.007 0.6346 0.6299 0.7966 0.7937

0.6590

0.6412 0.8118 0.8007 ISOKINETIC TESTING

SUMMARY 96.82 98.22

95.77

96.94 4.62% 5.46% 44.721 44.830

5.31%

5.13% 44.707 44.753COMPANY

NAME: General Shale Brick LOCATION: Mooresville, IN SOURCE TESTED: Kiln 32 DATE OF TEST: 01t24/07 RUN NO.:

HCL/HF/SO2/NOX Molecular Weiht of Stack Gas. Dry Bssiz, Md %CO2 %O2 2O Md 28.98 Volume of Water Vapor Coflec•d • 8TO. CONO., Vwv V]¢ 40.1 Vw(std) 2.108 Volume of Dry GSS Gallanted @ 8"rD, COND., Vm(•d) TIn(F) 68.400 Vm 46.890 Pb(inchas Hg)

30.100 dMta H

1.905 gamma 0 941 Vm(std) 44.721 Molntum Content of Stack Gas, Bwo Bwo 4.62% l-Bwo 95.38% Molecular Weight of Steak Gas, Ms Ms 28.45
• of •teck (enter diamnter in Inche•), • Depth•n 0 W'•tholn 0 diameter 42 No. Of 8tacks As(L'W)

0 As(alia.) 9.621119375

Stalk; (0.300)
Cp 0,84 qr(delta p)

0.797 Ts 236.100 Vs 51.585 Steak Gas Flowr•e, As

9.621119375 Qa 29779 8taOk Gas Flora • 8TD. COND., D W m,,m, Cl•d. Qstd (dscf/m)

21733.72 Q'•td (dScf/hr)

1304022.92 Vetedty at the Nozz•, Vn Oia, of Nozzte

0.25 T'm)e of Run

60 Vn 49.95 % IloklnMJo, %1 %1

96.82 % teoklr•io m•ssumd from intlmtmdlate vatues %1 97.19 Pollutant Mass Emission Rite, PMR, Ib•Jhr. Mn (g)

0.000897

0.0053 0.3402 0=0000 HF PMR (Ib/hr)

0.0577 PMR (ro/MMBtu)

0,0100 HC1, G•in= per aof gr/acf

0.0002 Groins per dsM gr/dscf

0.0003 Grains p•r mg/dscf m•dscf

0,2470 802 ppm

79.6• 802 •bS/hr

17.28495418 Nox ppm

51,67 Nox Ibs/hr

8.04503638

An(nozzle): 0.000341

0.006189 0.3979 0.0100 Total

0.2470 FIELD DATA

23456780101112131415161718192O21222324 0656 0.671 0700 0.670 0.670 0670 01620
0.600 0.600 0.620• 0.61i 0.620 0.620 0.6500.7,00 0.600 6.600 0.6000.•30

0.806 0,81• 0.837 0.31E 0.81• 0.819 O.78: 0.775 O.775 O,775 0.787 0.781 0.787 ,0.787i 0.CO 0.83' 0.771

O.794 12:4• 1.8•) 231

6C 2,0112.100 2.0t0 2,010 2.01( 1.1•0 1.100 1.1•0 1.1SO 1.8.10 1:1•0

1.10(il00 1.8•0 86•.69o538.800j 62 234 631

60 235! 69

6• •35 72

6• 235 72

6i 236 75

61 237 77

6• 237 75

63 237 77

65 238 78

• 236 72

65 235 71

66 235 72J

6• 235i 75

66 235 77

66 235 78

66 239 68

66 239 74

66 239 77

66 239 78

66

0.833COMPANY

NAME: LOCATION: SOURCE TESTED: DATE OF TEST: RUN NO.: POLLUTANT: Molecular Weight of Stack Gas, Dry Basis, Md %CO2 %02

Volume of Water Vapor Collected • STD, COND., Vwv Vw(std) 2.587 Volume of Dry Gas Collected @ 8TD. COND., Vm(std) Tm(F) 69.711 Vm 47.123 Pb(inches Hg)

-(, •,.•. delta H

1.893 Vm(std) 44.830 Moisture Content of Stack Gas, Bwo Bwo 5.46% 1-Bwo 94.54% Molecular Weight of Stack Gas, MS Ms 28.32 Area of Stack (enter diameter in inches), As DepCPin

No. of Stacks AS(L'IN)

0 As(die.) 9.621119375 Static Pressure, Ps PS

30.08 Stack Gas Velocity, Ve, fps Cp 0 sqr(delta p)

0.794 Ts 238,526 Vs 51,604 Stack Gas Flowrate, Qe, acfm As 9.621119375 Qs 29789 StackGae Flowrate•STD.

COND., DryBasis, Qetd. Q•d. 21477.19 Qstd (dscf•r)

1288631.23 Velocity at the Nozzle, Vn Din. of Nozzle Time of Run Vn

50.69 % Isokinetic, %1 %1

98,22 % •okineticmeaeured

from intermediate values %1 98.60 Pollutant Mass Emission Rate, PMR, Ib•./hr. Mn(g) PMR (l•/hr)

0.0673 PMR (tb/MMBtu)

0.0056 Grains per acf g/acf

0.0003 Grains per decf gr/dscf

0.0004 Grains per mgldscf mg/dscf

0.2932 SO2 ppm

60.2 SO2 Ibsfr•

12.87754965 Nox ppm

55.84 No× bs•"

8.591685874

0.4900 0.0000 An(nozzle) 0.000341

0.008794 0.5573 0.0056

0.2932 FIELD DATA

234
6789101112131415161718192021222324 Delta P

5c,0

IK- Factor Square Delta P0.849; 0.806 0.806 0.812 0.812 0.806 0.837 0,837 0.849 0.781 0,775• 0.775 0.714 0.775 0.77! 0.768 0.768 0.768 0.781 0.781 ]Sla• Ttme •ool [•op Time Volume DeltsH2 StaekTemp .D•M 2.160 1.950 •,,- 1,gfi 1.980 1.980 :•: 1.950 2.100 2.100 24( 2.160 1.830 1.800 1.800 1.530 1.809 1.800 2• 1,770 :"=, 1.770 1.770 1.830 ,• •,4 1.830 J3'i 84

0.631] 0.794 47.123 1.8•3 238.526

69.711COMPANY

NAME:

% B,m• LOCATION: I.; SOURCE TESTED: •,,:, DATE OF TEST: RUN NO.: POLLUTANT: Molecular Weight of Stack Gas, Dry Basis, Md %CO2 %02Md 28.92
Volume of Water Vapor Collected • STD. COND.. VWV VIcVw(std) 2.507 Volume of Dry Gas Collected (• STD. COND., Vm(etd) Tm(F) 76.275 Vm 47.566 Pb(inches Hg)

•:;, 1L,3 delta H

1.979 Vm(std) 44.707 Moisture Content of Stack Gas, Bwo Bwo 5.31% 1-Bwo 94.69% Molecular Weight of Stack Gas, Ms Ms 28.34 Area of Stack (enter diameter In Inches), As Depth-in Width-in o diameter No. of Stacks A=(L'VV)

0 As(dis.) 9.621119375 Static Pressure, Ps Static Ps 30.98 Stack Gas Velocity, Va, fps Cp •; sqr(delta p)

0.812 Ts 240.300 Vs 52,833 Stack Gas Flowrate, Qs, acfm AS 9.621119375 Qs 30499 Stack Gas Flowrate (• STD. COND., Dry Basis, Qstd. Qstd. 21966.82 Qstd (dscf/hr)

1318009.33 Velocity at the Nozzle, Vn Dis. of Nozzle

0 Time of Run

6•., Vn 50.60 % laoklnetlc, %1 %1

95.77 % I•oklnetlc measured from Intermediate values %1 96.13 Pollutant Mass Emission Rate, PMR, IbsJhr. Mn (g)

o: •;,724 0.009208 PMR (Ib/hr)

0.0640

0.5345 0.59846 PMR (IbtMMBtu)

0.00522

0.0000 0.00522 Grains per acf gr/acf

0.0003 Grains per dscf gr/dscf

0.0003 Grains per mg/dscf mg/dscf 0.271346011

0.271346 SO2 ppm

66,69 SO2 Ibs/hr

14.59107504 Nox ppm

53.14 Nox Ibs/hr

6.362658507

An(nozzle) 0.000341 FIELD DATA

234
676910
12131415161718192021222324 Delta p

700

0.660 Square Delta P 0.837 0.837 0.825, 0.825 0.806 0.79, 0.794 0.849 0.849 0.79z 0.781 0.79• 0.794 0.806 0.806 0.794 0.837 0.837 0.806 0.775 K-Facet

309]
Volume Delta H2 •tack ZI00 2.100 2.040 1.950 1.890 1.8901 2.160 2.160 1.890 1.83( 1,690 1.890 1.950 1.950 1.990 2.100 2,1009501.8001

0.8121 47,566 1.979 240.3•0•

76.275EMISSION SUMMARY SOURCE TESTED:

Plant 32 COMPANY NAME: General Shale DATE OF TEST: 1.24.07 PM/PM 10
Particulate Emissions • • i o.•q Condensibl.e• t 2.1• •• •onsensibl• 2.4704

Run2 •. Run3

• 0.0016• 0.0017

• 0.3212 0.3505

• 0.2942 0.0331

•_._.•.8274 0.6154 0.3836

•---•. 15--•-•--- •ck Vol. Flow Rate ACFM

33,628.53 DSCFM 24,370.68

[ 23,740.73

23,792.84

123,968.08
Stack Gas Velocity 237.600 58.255

• 240-200

t 241.400

t 239.733 56.889 57.063

57.402 0.7688 0.7800 •Head •t of Deffa P

0.8061 0.8978

0.7652 0.8747

] 0.8768

0.8831 ISOKINETIC TESTING

SUMMARY %lsokinetics: AIIowabl.__.•e isokinetic

90-110% % Moisture

of Stack Gas Sam•lume

96.65 5.09% 97.67

97.07 4.97% 4-•• • 489%

4.99% 50.056 49.443COMPANY

NAME: Gene•a] Shale LOCATION: M•oresville, IN •OURCE TESTED: Plan! 32 DATE OF TEST: 1.2407 RUN NO.:

PM,•M 10 Molecular Weight of Slack Gas, Dry Basis, Md %C02 %02 20 Md 28.96 Volume of Water Vapor Collected • STD. COND., Vwv VW(St•) 2.686 Volume of Dry Gas Collected • 8TD. COND., Vm(std) TIn{F) 68.375 Vm 52.416 Pt•inc•es Hg)

30 delta H

2,420 gar•ime 941
Moisture Content of Slack Gee, Bwo Bwo 5.09% l-Bwo 94.9t% Molecular Weight of Slack Gee, Me Ms 28.40 Area of •teck (enter dlame•r in inches), As Depth-In 0 W•dltHn diameter 42 No. of Stacks As(L'W)

0 As(din 9.621119375 Sletlc Pre•ure, Pa •af•C IO 300• PS 30.08 Stack Gee Velocity, Ve, fpe C• 084 sqr(de•a p) Ts

237.600 Ms •8.255 Slack Gas Flowrate, Qe, ecfm As 9.621119375 Qs 33629 Slack Gas FIowrete • 8TD. COND,, Dry Basis, Q•td. Qstd (dscf/m)

24370.68 Qstd (dscfR]r)

1462240,94 Velocity at the Nozzle, Vn Die. of Nozzle

0 25 Time of Run

60 Vn 56.30 % I•okinetl¢, • %1

96,65

Ar•L•le 0.000341

% I•oklnetlc meaaured from Intermediate values %1 97.02 Pollutant Mee•; Emlnlon Rate, PMR, Ib•/hr. Mn(g) 00049 0.0335 0.03836 PMR (Ib/hr)

0.3156 2,1549 2.4704 PMR (Ib•MMBtu)

0.0490 0.0000 0.0490 •ilterabl¢ CondenMble

Total Grains per ecf gt/acf

0,0011 Grains per d•cf gr/dscf

0.0015 Grains per mg/d•--f mg/dscf

1.2087

1,2087

RELD DATA

2 081( 3 0 840 4 0.840 5 o,.8•o 6 0880 7 0 830 8 0830 9 780 10 0 780 11 0760 12 0.74• 13 0 77O 14 057O 15 0 770 16 0 800 17 0 800 18 0 790 19 0 800 20 0.890 212223,24

0.900 0.917 0.917i 0.917 0.938 0.910.911 0.883 0,883 0.872 0.860 0.877 0.877 0.877 0.894 0.894 0.889 0.8940•94:
115 768 63.352

236 2.820 236 Z§20 237! 2.520 237 2.640 237 2.490 237 2.490 239 2.340 239 2.•ll) 239 •0 236236 2.310 236 2,310 236 Z310 236237 2.400 240 2.370 24124£ 2.670 24• 64

6; 6• 6• 71 6• 71 63 74 63 75 63 75 64 76 65 77 65 74 66 71 66 71 66 72 67 74 67 75 66 66, 66 7• 6• 74 66 76 66•COMPANY

NAME: General Shak, LOCATION: M oo!e•llie, IH 8OURCE TESTED: Pianl 32 DATE OFTEST:

2,i 0•' RUN NO.: •LLUTANT:

P•NPM •0 Enter Data lol•uter W•loht of •ck G• •q •i• ld

Md 28.• •o1• of Wel•r V•r Coll• • •TO. •ONO., • • 54
Volum • • G• •o11• • IT•. •O•., V•ld) T•e) 67.• Vm 51.078

• 0941
Moi•um Com•nt of •ck G• • • 4.97% 1-• •.•% iolculer Weight • •eck Gee, M• Ms 28.• Ar• of •¢k (enter di•er In Inch,), A• •in V•KI•I-ln 0 (•amete• 42 No. of Stacks As(L'W)

0 As(dis.) 9.621119375 •tatic Pre•ure, I• 8ta§c

(0.300•
8tsck Gas Velocity, V=, fpe =•r(de•ta p)

0.875 Ts 240.200 Vs 56.889 8tsck Gee Fiowrats, Q•, a¢fm AS 9.621119375 QS 32840 Stack GM Flowrats Q STD. COND., DW Bssls, Q•td. Qstd. 23740.73 Qstd (dscf/hr)

1424443.52 Velocity •t the Nozzl• Vn Dis. of Nozzle

0 25 Time of Run

60 Vr• 55.12 %lockin•i•%l %1 96.89 %l•oklnetlcme•sumdfromintermedlstevslue• %1 97.27 Pollutant Mass Emission Rate, PMR, IbsJhr. Mn (g)

0.005

0 0046 0.00958 PMR (10fr•)

0.3212

0.2942 0.6184 PMR (t•4MMBtu)

0.0243

0.0O00 0.0243 J•llterable C•e,d•n•ible

Total Grains per scf grk=cf

0.0012 Grains per d•cf gr/dscf

0.0016 Grains P•r mg/dscf rng/dscf

1.2566

1.2566 An(nozzle) 0.000341 FIELD DATA

084! 2 0 73( 3 770 4 0 770 0.790 6 0 799 7 07.90 8 0 790 9 0.920 10 0.84c 12 0 730 13 0 73t 14 0 720 15 0720 16 0.720 17 0.730 18 0 740 19 0 730 20 0 730 21222324

0.917 0,854 0.877 0,877 0.88£ 0.88£ 0.889 0.889 0.959 0.917 0.860 0.854 0.85• 0.849 0.849 0.849 0.854 0.86C 0.850.854

2.520

241 2.190 24O Z3101 240 2,310 242 2.370 242 2.370 242 2.370 242 2.37i 242 2.7•0 243 2.•20 240 2.220 236 •|•0 239 2.1•0 239 2.150 239 2.160 239 2.1•i 239 •t• 239240 2.1• 240 •1• 240 170 036 11&958

lSt•'rlme

43 I.::1)4111 L: •:::::DIIIi :C
57 6r! 60 60 63 59 66 59 68 60 69 60 71 62 72 61 73 61 69 62 74 63 75 63 78 64 76 64 79 65 80 66 80 66 81 66 81 66

0.7661 0.•751 51 0781 2.2981 240.2001

67.050COMPANY

NAME: Geqeral Sh3• LOCATION: M:,ores.;•te SOURCE TESTED: Plant 32 DATE OF TEST:

24 0: RUN NO.: POLLUTANT:

PM•F'M10 Enter Data MOIOCu sr WelgM of S•k Oss, D• •sl•, •d %CO2 %02 19 Md 28.92 V•um• • W•r V•r •11• I •. OOND., VIe 54 Vw(s• 2.•0 Volumt of D• Oa• •11• • STD. •D., V•) Tm(• 73.• Vm 52.242 Pb0nch• Hg)

30 1• de• H

2.• g•m•a 0.941 Vm(s•

• 4.• 1-• •.11• •ol•ul•r W•llhl • •ck Oss, • Ms
A• • •ck lair •iammr tn inch.), As Depth-in 0 Wide-in diameter 42 No. of Stacks •s(L*W)

0 As(dia.) 9.82111938 Static Pressure, Ps Static (0.300• Ps 30.08 Stack Gas Velocity, Vs, fps Cp 0 84 sqr(delta p)

0.877 Ts 241.4G0 Vs 57,063 •tack Gas Flowrate, Qs, acfm As 9.62111938 Qs 32940 Stack Gas Flowreta @ STD. COND., Dly Basis, Qatd. Qstd. 23792.84 Q•M (dscf/•r)

1427570.55 Velocity at the Nozzle, Vn Dia. of Nozzle

0 25 Time of Run Vn

55.73 % laokinettc, %1 %1

97.67 % laokinetlc measured from intermediate values %1 98.04 Pollutant Mass Emission Rate, PMR, Ib•J'nr. Mn (g)

0 0055 0 00052 0.00602 PMR (Ib/hr)

0.3505 0,0331 0.38364 PMR (Ib/MMBtu)

0.02641 00000 0.02641 Fi#erab/e Condensit Total Grains per acf grlacf

0.0013 Grains per dscf grldscf

0.0017 Grains per mg/dscf mgldscf 1.36431182

1.364812 An(nozzle) 0.000341 FIELD DATA

Run 3
23456789101112131415161718192021222324 0o 800 0 8O0 0 800 0 80O 0 600 0.920 0 800 0 760 0 730i 0 73C 0 730 0730 0.730 0 730 0 730 0 730 0 730 0 730

IK- Factor

3.00 I•lUarl Bllta Pi voh•m 0.90(]

2.430

243 0.89, •.400

24• 0.894 2.4•

243 0.894 2•

244 0.894 2.400

245 O.894 2.•

245 0,894 2.4•

245 0.959 2,760

244 0. 894

2.4• 0.872 Z•0

24 0.854 2.t• 0.8• 2.t•

239 0.85• 2.•i

239; 0.8• 2.t•

239 0.854 2.t•

240 0.8• 2,t•

24O 0.854 2.t•

2•0 0.8• 2.t•

240 0,8• 2.1• 2•8.392 176 150

op Time

17 38

69 66 72 67 74 66 75 6•.• 76 6£ 77 67 76 67 79 68 79 68 79 68 75 68 80 69 81 69 82 69 83 69 84 70 8,3 70 84 71 84 71 84 72

7701 0.8771 52.242l 2.3091 241.4001

73.625Analysis, Inc. General

Shale Brick, Inc. Project Number:

447

APPENDIX IH
FIELD DATAVELOCITY TRAVERSE

POINT DETERMINATION (EPA Method 1)

General Shale Brick Circular Stack Taver•e Points on Diameter: Stack Dia.(inches)?

Points:

Mooresville,

IN41 51

51

lOl

121 42

5789101tt2 2.81 1. 1.85

'1.34

•.09

0.88 10.50 6.13

3.44

2.81 31.50 39.19 12.43 29.57 35.87

4.418.15 13.5726.4337.59

6.139.49 14.36 27.64 32.513•.8•

4•967.43 10.•0 14.95

38.56 34.57 27.05 31.•0 37.04 39.15 41.124O
Table 7E-1 Analyzer

(or System)

Calibration

Error Data

Source T•st personnel: Date:. Time:

Low-level (or zero) calibration

l•as Mid-level calibration

•as High-level calibration

sas

Manufacturer Certified Cylinder Value (indicat• units)

Analyzer

or SyM•tn calibration

on, or data for sampling runs: Analyzer Model S•ial No.

R©f•'r• to data from the analy2•r calibration •rror t•st of• non-dilution

•yst•m. • R•fots to data from a 3-point •ystem •libmtion ,rror t©st of a dilution system.

3 Calibration

Span •CS, ): Analyzer calibration (indicate units) .7....°.:.• .• kZ.o.. 3.•.•

Absolute diffca•nc• (indicate units)

Calibration

Error (percent of calibration span)

A-•B x 100 CS

0?xAir Analysis,

Inc. 3904 Clarks Creek Road • Plainfield.

Indiana 46168 Tel. 317 837-8514

Fax. 317 837-8518

Certification Page

Air Analysis,

Inc. represents

that the information

provided

in this report is true and accurate.

We at Air Analysis, Inc. strive to remain true to our mission, that lhe people involved are people of integrity, the data acemate, and the reporting

timely. Sincerely,

Michael M. Dieen, President Air Analysis,

Inc.

STACK TESTING AND ENVIRONMENTAL

SERVICESTABLE OF CONTENTS
EXECUTIVE SUMMARY

(Page 2) Test Summary,

Table 1 Visible Emissions,

Table 1 RESULTS (Page 3) Particulate Matter

(PM) Emissions,

Table 2 & 3 Particulate Matter

< 10 micron

(PM10)

Emissions,

Table 2 & 3 Hydrogen Chloride

(HC1) Emissions,

Table 2 & 3 Hydrogen Flouride

(HF) Emissions,

Table 2 & 3 Sulfur Dioxide

(SO2) Emissions,

Table 2 & 3 Nitrogen Oxides

(NOx) Emissions,

Table 2 & 3 3. DESCRIPTION

OF PROCESSES

AND FIELD

NOTES

(Page 4) 4. METHODOLOGY

(Page 5) Summary of Sampling

Procedures Description of Sampling

Methods

APPENDIX SAMPLE

CALCULATIONS FIELD DATA

PRINTOUTS FIELD DATA LABORATORY

DATA CHAIN OF CUSTODY CALIBRATION DATA VISIBLE EMISSIONS

DATA SUBMITTED PROTOCOL PRODUCTION DATA IIIHIIVVVIVHVIIIIX.i ' Air Analysis

Inc. General

Shale Brick, Inc. Project Number:

447 ,,EXECUTIVE SUMMARY Air Analysis,

Inc. was contracted

by General

Shale Brick to perform

air emissions sampling of Kiln #32 during brick manufacturing

production

in Mooresville,

Indiana,

on January 24, 2007. The objective

of the test program

was to determine

compliance

with Indiana air permit requirements

and MACT

standards.

Sampling

was performed

for Particulate Matter (PM), Particulate

Matter < 10 microns

(PM10),

Sulfur Dioxide

(SO2), Nitrogen Oxides (NOx), Hydrogen

Chloride

(HC1) and Hydrogen

Flouride

fflF) emissions. Visible emissions

also coincided

during particulate

sampling.

The following

personnel
were involved

with the testing program: Air Analysis Air Analysis Air Analysis Air Analysis IDEM General Shale Michael

Dicen Susan Thorsell Marcus Allen Ron Stapert Jarod Fisher Warren Paschal The testing program

was performed

utilizing

US EPA Methods

1-5, 6C, 7E, 9, 26A, and 202. Three sets of one hour test runs were performed

on Kiln 32 on January

24, 2007.

TEST SUMMARY Table 1

Source

Kihl 32 Time

9:11- 13:a6

Mass Emissions (PM/PMI0) (PM/PMI0) 1.156 lbs/hr Sul.tbtes corrected

Mass Emissions (PM)(PM) 0.•291 lbs/hr

Hydrogen Chloride (lbs/hr)
(HCI) 0.06 lbs/hr

Hydrogen Flouride (lbs/hr)
(HF)0.45lbs/hr

Sulfur Dioxide (lbs/hr)
(SO2) 14.9lbs/luNitrogen Oxides (lbs/hr)
(NOx)8.3lbs/hr

0 % Opaci O, was read during all runs on Kiln #32Analysis, Inc. General

Shale Brick, Inc. Project Number:

447
RESULTS TEST CONDITIONS TABLE 2 KJLN 32 HCL/HF/SO2/NOx Gas Conditions 1 T•' 'Stack Temperature 235.1 BWO 4.6 02CO2Volumetric Flow Rate Qa Moisture

(vohm, e %) OxTgen (d•y volume %) Dioxide (dry volume %)
Actual eonOitions

{acfm)

2O

2

3 238.5 240 5.5 5.3 19 19 1 1 29, 778 29. 789 30. 498

Avg247,35.119

•o. 022 Qstd Stm•da•d Conditions

(dscfm)

21.733 21.725 Pollutant Results E(me)

Emissio•'• Rate. (lbs/hr) HC]

0.0577 0.3417.38

21,477

21.966 '0,0673 0.064 0.49 0,53 12.9 14.6 8,6 8.4 Emission Rate. (lbs/hr) HF Enfission Rate, (lbs/hr) SO2 Emission Rate. (lbs/hr) NOx 0.0630.4514.98.3

KILN 32 PM/PM10 Gas Conditions T$ 1237.61 Stack TempeFaturd g'41.4

'239.7 Bwo Moisture

(volume %}

5.1

5.0

4.9

5.0 02 Oxygen {dry volmne %•

20

19

19

19 Carbon Dioxide (du volume %)

1

1

1

1 Actaml C0n'ditions

(acfm)

33.628

•2.840' 33'.136 C02Volumetri• Flow Rate Standard Condiiions

(dscfm) Qstd 2.•.968"( Pollutant Results Ec

Emission'Rate.

(gr/dscf) PM

24.371

2'3.74'1 o.ooi5 0.o015 0.3156 0.3212 2.15 0.61 E(me)

o.6o1• 0.3505 0.38 Enfission Rate. (lbs/hr) PM PM/PMI0. (lbs/hr) 0.0016 0.3291 1.156

3.\Air Analysis,

Inc. General

Shale Brick, Inc. Pro.jecl Numbel:

447 METHODOLOGY The sampling procedures

used by Air Analysis, Inc. are as follows: Title 40 Method Method CFR Part 60 Appendix

A 1 "Sampling

of Velocity

Traverses

for Stationary

Sources" 2 "Determining

of Stack Gas Velocity

and Volumetric

Flow Rate" Method 3 "Gas Analysis

for the Determination

of Molecular

Weight" Method 4 "Determination

of Moisture

Content

in Stack Gas" Method 5 "Determining

of Particulate

Emissions" Method 6C "Determination

of Sulfur Dioxide" Method 7E "Determination

of Nitrogen

Oxides" Method 9 "Visual Determination

of the Opacity

Emissions" Method 202 "Determination

of Condensible

Emissions

from Stationary

Sources"
SAMPLE POINT

DETERMINATION-EPA METHOD

1 Sampling point locations

were determined

according

to EPA Reference

Method

1. Sampling Points Locations Dimensions Ports

Points Per Port

Total Points Kiln 32

42" I.D.

2

10

20 * * Exaat measure points and distances to disturbances

are listed in Appendix- Field Data
VELOCITY AND VOLUMETRIC

FLOW RATE

EPA METHOD

2 EPA Method 2 was used to determine

the gas velocity

and flow rate at the stack. Figure 4-2 includes the components

of the EPA Method

2 sampling

apparatus.

Each set of velocity determinations included

the measurement

of gas velocity pressure

and gas temperature

at each of the Method 1 determined

traverse points. The velocity pressures

were measures

with a Type S pitot tube. Gas temperature

measurements

made with a Type K thermocouple

and digital pyrometer.

GAS COMPOSITION

AND MOLECULAR

WEIGHT

EPA METHOD

3 In order to determine

the oxygen and carbon dioxide concentrations,

a sample of gas was obtained and analyzed

in accordance

with EPA Method 3. The gas sample was collected

using a Fyrite analyzer.

The results were used to determine

gas molecular

weight.

MOISTURE CONTENT-

EPA METHOD

4 The flue gas moisture

content at the testing locations

was determined

in accordance

with EPA Method 4. Figure 4-2 includes

the Method 4 sampling

components.

The gas moisture

was determined by quantitatively

condensing

moisture

in the chilled impingers

and silica absorption. The amount of moisture

condensed

was determined

gravimetrieally.

A dry gas meter was used to measure the volume of gas sampled.

Moisture

content is used to determine

stack gas velocity.Analysis, Inc. General

Shale B•°ick, Inc. P•o.ject Numbe•:

447
PARTICULATE DETERMINATION EPA METHOD

5/202 Stack gas is withdrawn

isokinetically

and particulate

matter is collected

on the nozzle, probe and filter. The probe temperature

and filter are maintained

at temperatures

of 248 degrees F (+/- 25 deg. F). The impinger

temperature

and exit gas is maintained

at temperatures

at or below 68 degrees F. The nozzle, probe and glass filter containers

are rinsed with acetone and the rinse is captured in a sealed glass container. (Method 202 only)The

impingers

and connecting

glassware

are rinsed twice with de-ionized water and captured

in a sealed container.

Two rinses of methylene

chloride

are captured

and stored in a sealed glass container

SO2 DETERMINATION EPA METHOD

6C Stack gas is withdrawn

from the stack and conditioned

(moisture

is removed)

before being analyzed by infrared detection.

Sulfur Dioxide molecules

are "excited"

by specific wave lengths. Molecular excitement

is directly proportional

to the concentration

of SO2. Quality assurance

of the analyzer

is first determined

by direct injection

of known EPA protocol

1 gas concentrations. A system check of the probe, connection

lines and conditioner

is also determined

prior to and after each sample period to determine

drift bias.

NOx DETERMINATION EPA METHOD

7E Stack gas is withdrawn

from the stack and conditioned

(moisture

is removed)

before being analyzed by chemilumineseent

detection.

NOx molecules

are "excited"

by specific wave lengths. Molecular excitement

is directly proportional

to the concentration

of NOx. Quality assurance

of the analyzer

is first determined

by direct injection

of known EPA protocol

1 gas concentrations. A system check of the probe, connection

lines and conditioner

is also determined

prior to and after each sample period to determine

drift bias.

OPACITY EPA METHOD

9 Stack opacity readings are taken for 60 minutes at 15 second intervals for NSPS and 30 minutes at 15 intervals

for state permitted,

non-federal

sources,

by a certified visible emissions

reader. The visible emissions

reading are conducted

during each of the particulate

test runs. The results are reported as an average opacity reading for the half an hour period. A copy of the visible reader's current certification

is included

in the Appendix.

HYDROGEN HALIDE

DETERMINATION EPA METHOD

26A Stack gas is withdrawn

isokinetically

and halides are collected

on the nozzle, probe and filter, sulfuric acid and sodium hydroxide.

The probe temperature

and filter are maintained

at temperatures of 248 degrees F. HCL is collected

in 0.1 N H2S04.

Chlorine

is collected

in 0.1 N NaOH. The impinger

temperature

and exit gas is maintained

at temperatures

at or below 68 degrees F. The impingers

and connecting

glassware

are rinsed twice with de-ionized

water and captured

in a sealed container.A_A• •alysis,

Inc. General

Shale Brick, Inc. Project Number:

447

APPENDIX I SA]tlPL E CALCULATIONSF'•jure 5-I. Metals & PartJculate

Sampling TrainA Air Analys•s,

Inc.

SAMPLE CALCULATIONS The table• pre•ntin 8 the re•ulta a•e generated ©lectronkally

•om raw data. It may not be ixmible to exa•y duplicate these t'e•lt• using • •alculater. The reference method dab r•ult• and all calculations

are carried to sL•een decimal pla•e• thmushout.

The •nal table is formatted to an appropriate number of signlficant figures.
1. Volume of water collected

(wscO V,,.,•= (0.04707X V•)

•ere: VkV•0.04707

total volume of liquid collected

in impingers

and silica gel (ml) volume of water collected at standard conditions

(fP) conversion factor (R3/ml)

2. Volume of gas metered, standard

conditions

(dsc0
(I 7.64X V,•)(P•.,,+ --•-• X•'•) 13.6 •,•- (460*/'.)

Where:

17.64 13.6460

barometric

pressure (in Hg) average dry gas meter temperature

(°F) volume of gas sample through dry gas meter at meter conditions

(It 3) volume of gas sample through dry gas meter at standard conditions

(if3) gas meter correction

factor (dimensionless) average pressure drop across meter box orifice (in HzO) conversion factor (°R/in Hg) conversion factor (in H20/in Hg) °F to °R conversion

constant Sample gas pressure (in Hg) v,=e•,o+(-i- •)

'Where: PbaroP•P,13.6

barometric

pressure (in Hg) sample gas static pressure (in H20) absolute sample gas pressure (in H•O) conversion factor (in H20/in Hg)A Air Analysis,

Inc.

Actual vapor pressure (in Hg)

ev vapor pressure,

actual (in Hg) absolute sample gas pressure (in Hg)

Moisture Content (%) V.,,•
proportion

of water vapor in the gas stream by volume volume of gas sample through the dry gas meter at standard conditions

(fP) volume of water collected at standard conditions

(fl•)

6. Saturated

moisture content (%)

Where: proportion

of water vapor in gas stream by volume at saturated

conditions

(%) vapor pressure,

actual (in Hg) absolute sample gas pressure (in Hg)

7. Molecular

weight of dry gas stream (lb/lb-mole) Md=M¢o" (C02) +Aim (02) +M.. ° v, (CO+N2) (I00) -(I00)

(I00)

Where: Md

O2CO + N, 100

dry molecular

weight of sample gas (lb/lb-mole) molecular weight of carbon dioxide (IWlb-mole) molecular weight of oxygen (IWlb-mole) molecular weight of carbon monoxide

and nitrogen (lb/lb-mole) proportion of carbon dioxide in the gas stream by volume (%) proportion of oxygen in the gas stream by volume (%) proportion of carbon monoxide

and nitrogen in gas stream by volume (%) conversion factor, %A Air Analysis,

Inc.

8. Molecular

weight of sample gas (lb/lb-mole)

MdB. dry molecular

weight of sample gas (lb/lb-mole) proportion of water vapor in the gas stream by volume molecular weight of water (lb/lb-mole) molecular weight of sample gas, wet basis (lb/lb-mole)

9. Velocity of sample gas (IVsec)

CpMsPst,Vs460 velocity pressure coefficient

(dimensionless) pitot tube constant molecular weight of sample gas, wet basis (lb/Ib-mole) absolute sample gas pressure (in. Hg) average sample gas temperature

(°F) average sample gas velocity (R/sec) °F to °R conversion

factor

10. Total flow of sample gas (acfi'n)

Where: As
Vs60

cross section area of sampling

location (t• •) volumetric flow rate at actual conditions

(acfin) sample gas velocity (fdsec) conversion factor, seconds to minutesA • Analysis,

Inc.

1. Total flow ofsample

gas (dscfm)

(t•','460)

BwoPsQaQstd17.64 460 proportion

of water vapor in the gas stream by volume absolute sample gas pressure (in. Hg) volumetric flow rate at actual conditions

(acfm) volumetric flow rate at standard conditions

(dscfm) average sample gas temperature

(°F) conversion factor, ((°R/in.Hg) °F to °R conversion

factor

12. Total flow of sample gas (dscth)
(Q=XP, X 17.64X -B.o)](60) [ (t.,*460)

Wliere: BwoPsQaQstd/hr t,17.64 460

proportion

of water vapor in the gas stream by volume absolute sample gas pressure (in. Hg) volumetric flow rate at actual conditions

(acfm) volumetric flow rate at standard conditions

(dscfmx60) average sample gas temperature

(°F) conversion factor, ((°R/in.Hg) °F to °R conversion

factorA Air Analysis,

Inc.

13. Percent Isokinetic

(%)

I•.. (°'°945°X T*X I'•) (•',X•',X•XOX• -BO

Where:
BwoIPsV•Vs00.09450

diameter of nozzle, inches proportion of water vapor int he gas stream by volume percent of isokinetic

sampling

(%) absolute sample gas pressure (in. Hg) average sample gas temperature

(°R) volume of gas sample through the dry gas meter at standard conditions

(fP) average sample gas velocity (fl/sec) total sample time, minutes constant

14. Pollutant

concentration

(gr/dscf) (15.43Xm•) C,•-

Where: C•d•fVm•td15.43

measured

concentration

in gas stream, grldscf pollutant collected,

corrected

for reagent blank, grams volume of gas sample through the dry gas meter at standard conditions conversion factor, grams to grains

15. Pollutant

Emissions,

Mass Emissions

Rate lbs/hr

E e•/•," (l•guctX 2.2046e -9 X Q,,aX 60

Where: E •r lag pollutant

2.2046e-9 60

Mass emissions

rate, pounds per hour micrograms of pollutant

emissions volumetric flow rate at standard conditions,

dry basis (dscfm) Volume Standard

conditions conversion factor, pounds per microgram conversion factor, minutes per hourA Air Analysis,

Inc.

16. Dioxin/Furan

Emission

Rate, lb/ton (Compliance

Determination)
.%,.. (c•,,,a(•2,,-,,,X•',), (P,,,,•) ii

Vc'here: E
K•P•

Mass emissions

rate, pounds per ton grain concentration

of pollutant

emissions volumetric flow rate at standard conditions,

dry basis (dsdh) conversion factor, 1 lb/7000 grains production rate tons per hour

17. Dioxin/Furan

Emission

Rate, pg/Mg (Compliance

Determination)

E (£t•/mX0.4536X

10•)

•'here:
E I•ton 0.4536 1090.907

Mass emissions

rate, microgram

per megagram Mass emissions

rate, pounds per ton conversion factor, kilograms

per pound conversion factor, micrograms

per kilogram conversion factor, tons per megagramPi•MVD TO LB/KR C LCUL T O S

ppm NO,

Ibs NO,

--

OR .PPm NO• 8:3755 x I0'

dscf .× 1.i94 × 10•'[ = !bs/NO, dscf Ibs NO•

dscf 60rain

IbsNO, dscf min

hr

2, SO:

•)pm $0.•

Ibs

• 6.01SI •" I0 • dscf

OR

ppm SOi x 1.660 x I0 "7 = Ibs/$O%. dscf .IbsSO: dscf

60min

IbsSO: dscf rnJn

hr

hr

3. CO

4. CH•

ppm CO 1.3762 x 107 Ibs "CO dscf Ibs CO dscf dscf.•n.

60min

Ibs CO

ppm CH.•

Ibs CH• (1 Bws) 2.4017 x I0 • dscf Ibs C.H• dscf

60 mJn Ibs CH( X _=_V_ × dscf nun

hr

hr

S, C•H, (1 Bws) 8.7573 × 10'

dscf IbsC,H, dsc# 60rain

Ibs ,,X•X•• dscf rain

hr

hro o. Or--.

(ludd) enleA0(tudd) enleA•ir Analysis,

Inc. General

Shale Brick, Inc. Project Number:

447

APPEND• • LABORA TOR Y DA TAJUN-O•-2005

21:34 From:PLANT

22 DISPATCH

9197747251 To:9197746634 P.1•1Air Analysis, Inc. 3904 Clarks

Creek Road Plainfield, IN 46168
Analytical Report (0107-72)

EPA Method

26 Hydrogen fluoride Hydrogen chloride HPLC Analysis Sulfate
Enthalpy Analytical, Inc. Phone: (919) 850 4392 / Fax: (919) 850 9012 / www, enthalpy.com 2202 Ellis Road Durham, NC 27703 5518cortify that to tho b•st of my knowledgo

all analytical

data pros•nted

in this report: * Havo boon chcckod for complotenoss

• Are accurate,

error-free,

and legiblo

• Have been conducted

in accordance

with approved

protocol,

and that all deviations

and analytical p•oblems are summarized

in the appropriate

narrafivo(s)

• This analytical

report was prepared in Portable Document

Format (.PDF) and contains 133 pages.

QA Review

Performed

by: Ann L. H. Morris

Page 2 of 133Summary of Results

Page 3 of 133CompanyJAir Analysis,

Inc. AnalystlKAM ParameterslEPA Method 26 # Samples

J3 runs & 1 blank Client #JN/A Job #•0107-72 PO #JVerbal Report DateJl/30/2007 Compound
Hydrogen Fluoride Hydrogen Chloride Run 1 5,292897
Hydrogen Fluoride Hydrogen Chloride Blank 12.9 ND 33.6 J Sample

ID / Catch Weight

(ug)

Run 2 7,7321,062

Run 3 8,224984

Page 4 of 133 0107-72 m26 Results 2/1/2007CompanyJh,ir h,nal•sis,

Inc, h,nalystlKEH ParameterslHPLC h,nalysis # Samplesl3

runs Client #iN/h, Job #J0107-72 PO #JVerbal Report.Date 11/30/2007 Compound

Sulfate Sample

ID / Catch Weight

RID1 3,094 R2D1 1,891 R3D1 2,149

Page 5 of 133 0107-72 Sulfate Results 1/30/2007Results

Page 6 of 133oo•.wo. 2Narrative Summary

Page 10 of 133Compan Analyst Parameters # Samples Custody

Analysis

Calibration

Chromatographic Conditions

Enthalpy

Analytical

Narrative

Summary
Air Anal.vsis.

Inc. KAM EPA Method 26 3 runs & 1 blank Client # N/A Job # 0107-72 PO # Verbal Report Date January 31, 2007 Erin Ortiz received

the samples

on 1/26/07 after being relinquished

by Air Analysis,

Inc. The samples

were received

in good condition

at 8.4 °C. A chain of custody was not received

with the samples. Prior to and during analysis,

the samples

were kept under lock with access only to authorized

personnel

by Enthalpy

Analytical,

Inc. The samples were analyzed

for hydrogen

fluoride and hydrogen

chloride using the analytical

procedures

in EPA Method

26, Determination

of Hydrogen Halide and Halogen

Emissions

from Stationary

Sources Non-Isokinetic Method (40 CFR Part 60, Appendix

A). The samples

were analyzed

following

the procedures

in Section 11.0, Analytical Procedures.

All samples and standards

were prepared,

stored, and analyzed

using high-density

polyethylene

containers. The Agilent Model 1100 High Performance

Liquid Chromatograph ("Gonzo") was equipped

as follows: Front: DIONEX

ED40 Electrochemical

Detector Front: Dionex Ion Pac AS 14A, 4 x 250 mm (S/N 004604) Rear: NA Rear: Dionex Ion Pac AS 14A, 4 x 250 mm (S/N 003055) The calibration

curves are located in the back of this report and referenced in the Analysis

Method column on the Detailed

Results page. For each calibration

curve used, the first page of the curve contains

all method specific parameters

(i.e., curve type, origin, weight, etc.) used to quantify the samples.

The calibration

curve section also includes

a table with the Retention

Time (RetTime),

Level (Lvl), Amount (corresponding units), Area, Response

Factor (Amt/Area)

and the analyte Name. The calibration

table is used to identify

(by retention time) and quantify

each target compound. The acquisition

method COLSWTCH.M

is included

in the Curve/QA Chromatograms section of this report.

Page 11 of 133QC Notes

Reporting Notes

Enthalpy

Analytical

Narrative

Summary (continued)

As required

in Section

7.2.2, Absorbing

Solution

Blanks,

a client-provided reagent

blank was analyzed.

Additionally,

a quality control check sample was analyzed

at the same time as the blanks and samples. Unless otherwise

specified,

all method-required

acceptance criteria were met. All sample preparation

and analytical

holding

times specified

in the method were met unless otherwise

indicated.

In Section 13.2, Sample Stability, the specified

analytical

holding time is four weeks. The instrument

was set up using two columns

of the same type to reduce the total time needed to run all the samples.

Each sample was analyzed with two injections,

one injection

on each of the columns.

Because

the two injections

were not on the same column,

the retention

times varied slightly more than our internal criteria of 3%. However,

the response was similar on the two columns

(as can be seen in the passing calibration curves), so the sample concentrations

are accurate. The H2804 Inatrix samples were analyzed

for F- and CI- but are reported as I-IF and HCI. The peaks listed in the "Sample

Chromatograms" section are labeled hydrogen

fluoride

and hydrogen

chloride.

The additional molecular

weight contribution

from the H+ is included

in the results listed on each chromatogram

and throughout

the report. Enthalpy Analytical,

Inc. is accredited

to perform

this method

for compliance purposes

by the Louisiana

Environmental

Laboratory Accreditation Program

(LELAP),

certificate

number 04010.

Page 12 of 133Enthalpy Analytical

Narrative

Summary Company Air Anal.vsis.

Inc. Client # N/A Analyst KEH Job # 0107-72 Parameters HPLC Analysis PO # Verbal # Samples

3 runs Report Date January 31, 2007 Custody Erin Ortiz received

the samples on 1/26/07 after being relinquished

by Air Analysis,

Inc. The samples

were received

in good condition

at 8.4 °C. A chain of custody was not received

with the samples. Prior to and during analysis,

the samples

were kept under lock with access only to atrdaorized

personnel

by Enthalpy

Analytical,

Inc. Analysis The samples were analyzed

for sulfate using general HPLC procedures. The Agilent Model 1100 High Performance

Liquid Chromatograph ("Curly") was equipped

as follows: Front: DIONEX

ED40 Electrochemical

Detector Front: Dionex Ion Pac AS14A,

4 x 250 mm (S/N 2243) Calibration The calibration

curve is located in the back of this report and referenced in the Analysis

Method column on the Detailed

Results page. For each calibration

curve used, the first page of the curve contains

all method specific parameters

(i.e., curve type, origin, weight, etc.) used to quantify the samples.

The calibration

curve section also includes

a table with the Retention

Time (RetTime),

Level

(Lvl), Amount (corresponding units), Area, Response

Factor (Amt/Area)

and the analyte Name. The calibration

table is used to identify

(by retention time) and quantify

each target compound. Chromatographic The acquisition

method

0107-45.M

is included

in the Curve/QA Conditions Chromatograms

section of this report. QC Notes

All sample preparation

and analytical

holding

times specified

in the method were met unless otherwise

indicated. Reporting Notes

None

Page 13 of 133General Reporting

Notes The following

are general reporting

notes that are applicable

to all Enthalpy

Analytical,

Inc. reports, unless specifically noted otherwise.

• The symbol MDL represents

the Minimum

Detection

Limit Below this value the laboratory

cannot confun the presence of the analyte of interest reliably.

• The symbol LOQ represents

the Limit of Quantification.

Below this value the laboratory

cannot quantitate the analyte of interest within the criteria of the method.

• The symbol ND following

a value indicates a non-detect

or analytical

result below the MDL.

• The symbol J following

a value indicates

an analytical

result between the MDL and the LOQ. A J flag indicates that the laboratory

can positively

identify the analyte of interest as present, but the value should be considered

an estimate.

• The symbol E following

a value indicates an analytical

result exceeding

100% of the highest calibration point.

• The symbol DF represents

a Dilution Factor. This number represents

dilutions

during the extraction and/or laboratory

stages of sample treatment.

The analytical

result taken from a laboratory

instrument

is multiplied by the DF to get final results.

• The Sample ID MS represents

a Matrix Spike. An aliquot of an actual sample is spiked with a known amount of analyte so that a percent recovery

value can be determined.

This shows what effect the sample matrix may have on the target analyte, i.e. whether or not anything in the sample matrix prohibits analysis for the analyte(s).

• The Sample ID MSD represents

a Matrix Spike Duplicate.

Prepared

in the same manner as an MS, the use of duplicate

matrix spikes allows further eonfh-mation

of laboratory

quality by showing

the consistency of results gained by performing

the same steps multiple times. Most methods performed

by Enthalpy do not require analysis of an MSD.

• The Sample ID B.c/represents

a Blind Spike. A member of the Quality Assurance

department

has ere'ated BS samples for many of the analytes Enthalpy tests for, and only QA and the Enthalpy Analytical ownership have access to the actual values of these samples.

The laboratory

analyzes

them without knowledge of the actual value, and the spreadsheets

get completed

for these samples solely by the QA

• The Sample ID LCS represents

a Laboratory

Control Sample. Whenever

spikes are prepared

for our clients more spikes are prepared

than needed. The extras (randomly

chosen) are kept in-house

at the appropriate temperature

conditions.

When the spike samples come back from the client for analysis, the LCSs (usually two are saved) are analyzed

to confirm that the analyte could be recovered

from the media, separate from the spike samples which were used on the project and which may have had issues caused during collection

and/or transport.

• Significant

Figures:

Where the reported value is much greater than unity (1.00) in the units expressed (specifically values of 1,000 or greater), the number is rounded to a whole number of units, rather than to 3 significant

figures. For example,

a value of 10,456.45

ug catch is rounded to 10,456 ug. There are five significant digits reported, but no confidence

should be placed on more than three significant

digits.

Page 14 of 133Sample Chromatograms

Page 17 of 133Data

File H:\LC2007QI\GONZO\DATA\JAN\0107-72B\011-1001.D 0107-72 Sample

Name: Run
Injection Date

1/26/2007

5:47:32

PM

Seq. Line

I0 Sample Name

Run i*i0 Location

Vial ii Acq. Operator

KAM Inj

1 Acq. Instrument

Gonzo Inj Volume

25 •i Acq. Method

H: \LC2007QI\GONZO\METHODS\COLSWTCH.M Last changed

1/26/2007

3:10:41

PM by KAM Analysis Method

H:\LC2007QI\GONZO\METHODS\0107-72B.M Last changed

1/29/2007

9:08:29

AM by DJR ADO1 8, Dionex 1.D) u8

440.

1.5

2

2.5

3

3.5

4

4.5

m____•i

External Standard

Report

Sorted By Signal Calib. Data Modified 1/29/2007

9:08:11

AM Multiplier 1.0000 Dilution 1.0000 Use Multiplier

& Dilution

Factor with ISTDs Signal i: ADCI B, Dionex

ED 40 RetTime Type

Axea

Amt/Area

Amount [min] [uS*s] [ug/mL] 2.501 MM

201.00441

1.04602e-2

2.10254 Totals 2.10254

Grp Name Hydrogen Eluoride

•snuallnte•ti0n(KAM)•

Results obtained

with enhanced

integrator!

*** End of Report

***
Page 18 of 133 Instrument 3 1/29/2007

12:14:24

PM DJR Page 1 of 1Air Analysis

Inc. General

Shale Brick, Inc. Project Number:

447

Kiln 32Filter623624625 PM DETERMINATION FILTER

Run #

Pre-Weight
1 0.3701 2 0.3665 3 0.3704

Post-Weig

ht 0.3722 0.3695 0.3734

Net Gain 0.0021 0.0030 0.0030

Kiln 32Beaker ID
Z12 Acetone Beaker (50mls) ACETONE
Run #

Pre-Weight
1 80.1370 2 55.1905 3 53.6844 56.1264

Post-Weight 80.1398 55.1925 53.6869 56.1264 Net Gain 0.0028 0.0020 0.0025 0.0000

Kiln 32 Run #
1
2
3 TOTAL
Filter Net Gain 0.0021
0.003
0.003

Acetone

Net Gain 0.0028
0.002
0.0025

Totals
0.0049
0.005
0.0055Analysis, Inc. General

Shale Brick, Inc. Project Number:

447
CONDENSIBLE DETERMINATION n2__QO Kiln 32Beaker ID

Run #

FF Blank Beaker Pre-Weight

Post-Weight

Net Gain DD 1

80.7623

80.7932

0.0309 EE 2

54.1080

54.1120

0.0040 3 77.6275

77.6298

0.0023 (500mls H20)

65.7854

65.7854

0.0000

D[/SULFATE CALCULATIONS
Kiln 32 Beaker Run ID

DD 1
EE 2
FF 3

DI

DI

DI Total Net Gain

Sulfate

Net minus Net Gain Inhouse

Lab Sulfate = Volume Volume

Volume

(grams)

(glml)

Grams 0.0309 332

50

382 0.03555

0.00006188

0.03246 0.0040 300

50

350 0.00467

0.00003782

0.00278 0.0023 350

49

399 0.00262

0.00004298

0.00052
DI net gain grams x (total mls/(total

mls aliquot)

sulfate grams

corrected

gainAnalysis, Inc. General

Shale Brick, Inc. Project Number:

447

CONDENSIBLE DETERMINATION (Continued)

Kiln 32Beaker ID

BBCC Blank'Beaker MeCI2

Run #

3 (50mls MeCI2)

Pro-Weight 56.0970 56.0485 77.3114

Post-Weight 56.0980 56.0503 77.3114

Net Gain 0.0010 0.0018 0.0000 79.1611 79.161t

0.0000

TOTAL Kiln 32Run #

H20 Net Gain 0.03246
2 0.00278
3 0.00052

MeCI2 Net Gain 0.001

Totals
0.03346 0.0018 0.00458
0 0.00052

9,2kAir Analysis,

Inc. General

Shale Brick, Inc. Project Number:

447

APPENDIX V CHAIN OF CUNTODYSample Custody

Page 15 of 13300,•'.kAir #malysis,

Inc. General

Shale Brick, Inc. Project Number:

447

APPEND• • CALIBRATION DATA7•

7•
7i

7•17•317) 837- 8514 ('317) 837- 8518 FAX 3904 Clarks

Creek Road Plainfield, Indiana

46168

PITOT TUBE

CALIBRATION Reference: 40 CFR 60, Appendix

A, Method 2, Secbbn 2.1 Calibration Date Probe Number/ID..,

1/05/2007 Six Foot Pmbe-A
External Tubing Diameter Base To Opening Plane Distance

(Pa). Base To Opening Plane Distance

(Pb),, 0.95 1.25 cm 1.25 cm Pb/Dt Pa/Dt Angle a I Measured

Angle p 1 Angle p 2 1.32cm 1 o32cm 1 deg Angle ¢= 2 1 deg 0 deg 0 deg

z (cm) 0.0
w (cm) 0.0 If all cdteda are me• Pitot Coefficient

is O. 84

Allowable 1.05DtsP<l.50Dt (0.997,5cm 1.42cm) 1.05Dt•;Psl.50Dt (0.9975cm 1.42cm) and c• 2 < 10.0 Degrees and (] 2 < 10.0 Degrees and 13 2 a 5.0 Degrees and 13 2 < 5.0 Degrees

z is less than 0.32cm (11s%

w is less than 0.08cm (1/32nd") Pitot Coefficient:0.84 Coii•ul Factor

Mercury

Thermometer

"F ICE 35 AMBIENT 55 56 BOILING/HOT H20 106 107

Test performedby:

,••"•

•;;•&

Date of Test:

1/5/07(317) 837- 8514 (317) 837- 8518 FAX 3904 Clarks

Creek Road Plainfield, Indiana

46168

PITOT TUBE

CALIBRATION Reference: 40 CFR 60, Appendix

A, Method 2, Section 2.1 Calibration Date Probe Number/ID.

1/O5/2007 Six Foot Pmbe-B
External Tubing Diameter Base To Opening Plane Distance

(Pa) Base To Opening Plane Distance

(Pb) 0.95 1.25 cm 1.25 cm
Pb/Dt Pa/Dt Angle a 1 Angle a 2 Angle I• 1 Angle I• 2

z (cm)

w (•..•) Measured 1.32cm 1.32cm 1 deg 1 deg 0 deg 0 deg0.00.0 If all criteria are me• Pitot Coefficient

is 0.84 Uoi•u/ Factor

Mercury

Thermom_•._r

"F

AIIc;;¢ble 1.05DI•P<I.50Dt (0.9975cm 1.42cm) 1.05DtsP<I .50Dt (0.9975cm 1.42cm)

a I and a 2 < 10.0 Degrees and a 2 < 10.0 Degrees and I• 2 < 5.0 Degrees and I• 2 < 5.0 Degrees

z is less than 0.32cm (1/8 =•)

w is less than 0.08cm (1/32nd") Pitot Coefficient:0.84

ICE 34 AMBIENT 56 56 BOILING/HOT H20 107 lO8 Probe Res•nonse 33

Test performed

by: Date of Test:Certificate of Analysis _EPA Protocol •di• e il•t•l•t•!,

Procedure

G1 Notice: This Cylinder

is not to be used when pressure is under 150 psig. Manufactured and certified at." Produced

for customer: Linde Gas LLC Maumee Specialty

Gas Plant 6421 Monclova

Road MAUMEE OH 43537 419-893-7226 Material: 6681 EPA SO2/N2

100-3500

PPM Production #:

100125813 Lot #: 02499J6280JA Cylinder #:

CC154356 Expiration Date:

10/12/2008 Shelf Life: 24 months

A31

LINDE COLUMBUS

INTERBRANCH 450 GREENLAWN

AVE COLUMBUS OH 43223 USA614-443-7487 • \• ") •/• Blend Tolerance:

5 % Relative Blend Type:

EPA Protocol Cyl. Pressure: 2000 psig Balance Gas:

Ni•trogen CGA: 66O Analytical Accuracy:

1.00 % Relative Confidence: 95 %

7446-09-5 Sulfur Dioxide 360

358 +/- 3.6 ppm

10/12/2006 7727-37-9 Nitrogen Balance 10/12/2006
7446-09-5 Sulfur Dioxide CC100283

GMIS

503.5 ppm

09/27/2007

All analyses are performed

under controlled

environmental

conditions.This

product is manufactured

using equipment

which has been calibrated

with NIST traceable,

or equivalent,

standards,

weights,

or equipment.

Analytical report approved

by Roy Yoder ertificatiquib e Onologp orporation Industry Leader in Specialty

Gases, Equipment

and Service Certificate of Analysis EPA PROTOCOL

GAS Customer Date_Delive _ry Receipt Gas Standard Purchase Order Final Analysis

Date Expiration Date Analytical Data EPA Protocol,

Section No. 2.2•!Procedure

G-1 1E Monitoring

Instruments,

Inc (Worthington,

Ohio) December 11, 2006 DR-18365 811.0 ppm Sulfur Dioxide/Nitrogen

EPA PROTOCOl, 789_._•2 December 06, 2006 December 06, 2008 DO NOT USE BELOW

150 psig

Reolicate Concentrations Sulfur Dioxide:

772.1 ppm +/- 7.7 atom Nitroeen: Balance Reference Standard(s): SRM/GMIS: Cylinder Number: Concentration: Expiration Date: GMIS CC-81408 721.2 pprn SO2/Nitrogen October 13, 2008

GMIS CC-56592 913.4 ppm SO2/Nitrogen September 07, 2009 Certification Instrumentation Component: Make/Model: Serial Ntnnber: Principal of Measurement: Last Calibration: Sulfur Dioxide Nicolet NEXUS 470 AEP99000154 FTIR December 06, 2006 ,Cylinder Data Cylinder Number: Cylinder Outlet: Expiration Date:

CC-251962 CGA 660 December 06, 2008 Cylinder

Volume: Cylinder Pressure:

140 Cubic Feet 2000 psig, 70F Analytical uncertainty

and NIST Traceability

are in compliance

with EPA-600/R-97/121.

Certified by: Date:

December

11, 2006

Unmatched Excellence
2564 Pemberton

Drive Apopka, Florida 32703 Phone (407)-292-2990 Fax (407)-292-3313Certificate of Analysis

Procedure

GI Notice: This Cylinder

is not to be used when pressure is under 150 psig. Manufactured and certified at: Produced

for customer.. Linde Gas LLC Maumee Specialty

Gas Plant 6421 Monclova

Road MAUMEE OH 43537 419-893-7226 Material: 6599 EPA NO/N2 50-499 PPM

A31 Produ.etion #:

100125920 Lot #: 02499J6280AX '•Cylinder #:

-CC231133 Expiration Date:

10/10/2008 Shelf Life: 24 months LINDE COLUMBUS

INTERBRANCH 450 GREENLAWN

AVE COLUMBUS OH 43223 USA614-443-7487 I•3\•'• Blend Tolerance:

5 % Relative Blend Type:

EPA Protocol Cyl. Pressure: 2000 psig Balance Gas:

Nitrogen C•GA: 660 Analytical Accuracy:

1.0(i % -R•la•iw Confidence: 95 %

10102-43-9 Nitric Oxide ••

•••'" ""•"i•'"•" •• •

i"•ii•••• 7727-37-9 Nitrogen Balance 10/10/2006
N/A NOx 448 ppm

10/10/2006
•ol0z-,•3-u •tnc ox•ae ,CC10150

•, GMIS

246.3 ppm

05/27/2007
Horiba CLA-510SS 568093024 Chemiluminescence 09/05/2006
All analyses are performed

under controlled

environmental

conditions.This

product is manufactured

using equipment

which has been calibrated

with NIST traceable,

or equivalent,

standards,

w•eights,

or equipment.

Analytical report approved

by Roy Yoder ertificatCertificate of Analysis

Procedure

G1 Notice: This Cylinder

is not to be used when pressure is under 150 psig. Manufactured and certified at: Produced,

for customer.. Linde Gas LLC Maumee Specialty

Gas Plant 6421 Monclova

Road MAUMEE OH 43537 419-893-7226 LINDE COLUMBUS

INTERBRANCH 450 GREENLAWN

AVE COLUMBUS OH 43223 USA614-443-7487 • \ ,•,• Material: 6599 EPA NO/N2 50-499 PPM Production #:

100125819 Lot #: 02499J6280AY Cylinder #:

CC168919 Expiration Date:

10/10/2008 Shelf Life: 24 months

A31

Blend Tolerance:

5 % Relative Blend Type:

EPA Protocol Cyl. Pressure: 2000 psig Balance Gas:

Nitrogen CGA: 660 Analytical Accuracy:

1.00 % Relative Confidence: 95 %

•u•vz-,•3-u Nitric Oxiae 275

270 +/- 3 ppm

•)•)•• 7727-37-9 Nitrogen Balance 10/10/2006 N/A NOx 270 ppm

10/10/2006
10102-43-9 Nitric Oxide CC10150

GMIS

246.3 ppm

05/27/2007
Horiba CLA-510SS 568093024 Chemiluminescence 09/05/2006
All analyses are performed

under controlled

environmental

conditions.This

product is manufactured

using equipment

which has been calibrated

with NIST traceable,

or equivalent,

standards,

weights, or equipment.

Analytical report approved

by Roy Yoder g ertificatCertificate of Analysis

• •,,,•L •...•PA P•otocol, rfor[n•]d. •c•;orai,•

•.• •4.',•D(•/•).l,

Procedure

G1 Notice: This Cylinder

is not to be used when pressure

is under 150 psig. Manufactured and certified at: Produced

for customer: Linde Gas LLC Maumee Specialty

Gas Plant 6421 Monclova

Road MAUMEE OH 43537 419-893-7226 Material: 2241 LINDE COLUMBUS

INTERBRANCH 450 GREENLAWN

AVE COLUMBUS OH 43223 USA614-443-7487

A31 Blend Tolerance:

5 % Relative Blend Type:

EPA Protocol Cyl. Pressure: 2000 psig Balance Gas:

N•rogen CGA: 660 Analytical Accuracy:

1.00 % Relative Confidence: 95 % EPA MISC 2 COMPONENT Production #:

100126003 Lot #: 02499H4310S•I Cylinder #:

CC59286 Expiration Date:

10/25/2008 Shelf Life: 24 months

7446-09-5 Sulfur Dioxide 480

482 +/- 5 ppm

10/25/2005 7727-37-9 Nitrogen Balance 10/25/2006
Sulfur Dioxide CC163555

GMIS

503.7 ppm

09/27/2007 Horiba VIA-510 4131546004 Non-Dispersive

Infrared

09/07/2006
All analyses are performed

under controlled

environmental

conditions.This

product is manufactured

using equipment

which has been calibrated

with NIST traceable,

or equivalent,

standards,

weights,

or equipment.

Analytical report approved

by Roy Yoder Certificateiquib ec nologp ( orporatiOn_o.,.o,, Industry Leader in Specialty

Gases, Equipment

and 8erviee •,,.-. •,• Certificate of Analysis EPA PROTOCOL

GAS Customer Dat.___•eDelive _ry Receipt Gas Standard Purchase Order .Final Analysis

Date •n Date EPA._ P.r0tocol_,

Secti_on No.: 2..•.•P.rocedure

G-1 a_ I_E Monitoring

Instruments,

Inc (Worthington,

Ohio) February_ 06, 2006 DR-16649 _240.0 ppm Sulfur Dioxide/Nitrogen

EPA PROTOCOL 700____•6February_ 06, 2006 February 06, 2008 •

DO NOT USE BELOW

150 psig Replicate Concentrations Sulfur Dioxide:

231.9 ppm +/- 2.3 ppm Nitroeen: Balance Reference Standard(s): SRM/GMIS: Cylinder Number: ConcentratiOn: Expiration Date: Certification Instrumentation Component: Make/Model: Serial N .u!nber: Principal of Measurement: Last Calibration: GMIS CC-125484 99.6 ppm SO2/Nitrogen July 08, 2006

Sulfur Dioxide Nicolet NEXUS 470 AEP99000154 FTIRFebruary 02, 2006

GMIS CC-117931 246.9 ppm SO2/Nitrogen February25,2009

Cylinder Data Cylinder Number: Cylinder Outlet: Expiration Date:

CC-159003 CGA 660 February06,2008

Cylinder

Volume: Cylinder Pressure:

140 Cubic Feet 2000 psig, 70F Analytical uncertainty

and •ST Traceability

are in compliance Certified by:

•

[••

with EPA-600/R-97/121.

Date: February

06, 2006 • (aoo) 532-747

Unmatched Excellence
2564 Pemberton

Drive Apopka, Florida 32703 Phone (407)-292-2990 Fax (407)--292-3313Industry Leader in Specialty

Gases, Equipment

and Service Certificate of Analysis EPA PROTOCOL

GAS Customer Dat____ge...Delivery Receipt _Gas Standard Purchase Order _Final Analysis

Date •ion Date
EPA. protocol:

Section No. 2. 5 Procedure

G-1 a. I_E Monitoring

Instruments,

Inc (Worthington,

Ohio) February 06, 2006 _DR-16649 ..240.0 ppm Sulfur Dioxide/Nitrogen

EPA PROTOCOl, 700___.•6February 06, 2006' February 06, 2.008 •l• ^

DO NOT USE BELOW

150 psig
Replicate Concentrations Sulfur Dioxide:

231.9 ppm +/- 2.3 ppm Nitro•,en: Balance Reference Standard(s): SRMdGMIS: Cylinder Number: Concentration: Expiration Date: Certification Instrumentation Component: Make/Model: Serial Number: Principal bf Measurement: Last Calibration: GMIS CC-125484 99.6 ppm SO2/Nitrogen July 08, 2006

Sulfur Dioxide Nicolet NEXUS 470 AEP99000154 FTIRFebruary 02, 2006

GMIS CC-117931 246.9 ppm SO2/Ni•ogen February25,2009

Cylinder Data Cylinder Number: Cylinder Outlet: Expiration Date:

CC-159003 CGA 660 February 06, 2008

Cylinder

Volume: Cylinder Pressure:

140 Cubic Feet 2000 psig, 70F Analytical uncertainty

and •IST Traceability

are in compliance •/•, •

with EPA-600/R-97/121. Certified by:

•

[(•,/•g,d,¢.• Date: February

06, 2006 (8oo) 532-747

Unmatched Excellence
2564 Pemberton

Drive Apopka, Florida 32703 Phone (407)-292-2990 Fax (407)-292-3313AAir Analysis,

Inc. General

Shale Brick, Inc. Project Number:

447

APPENDIX VII VISIBLE EMISSIONS

DATACARL KOONTZ

ASSOCIATES of Nashville, Tennessee is is to ack,•ledge

that successfully participated

In Visible Emissions tralnlng on.. and is qualified to evaluate Visible Emissions for a pedod of six (6) months from the date of certification.
InstructorOF READINGS WErE

C•RT•IEO BY Comments:XRUN NUMB

X

Plume

NIGHE S r PE,•IO0

C£RT•IEO BY Comments:•ir Analysis,

Inc. General

Shale Brick, Inc. Project Number:

447

APPENDIX VIH SUBMITTED PROTOCOL•__•a•h" •ysis,

Inc. General

Shale Brick, inc. Project Number:

447

APPE• • PROD UCTION

DATAMooresville Plant 32 Jaunary

24, 2006 Testing 180.00 Cars/Week 25.71 Cam/day 5760.00 Brick/Car 3.60 Ibs/brick

Fired Weight 11.11 tons/hour

Production

Rate Bicarb Fe• Rate

25% 216 Ibs/hourMooresville Plant 32 Jaunary

24, 2006 Testing 180.00 Cars/Week 25.71 Cars/day 5760.00 BdcldCar 3.60 Ibs/bdck

Fired Weight 11.11 tons/hour

Production

Rate Bicarb Feed Rate

25% 216 Ibs/hour