PARTICULATE/HF/HCI EMISSIONS

TESTING ON THE SCRUBBER/BAGHOUSE

EXHAUST OF TUNNEL KILN #1 BORAL BRICKS,

INC. AUGUSTA PLANT 4 1630 ARTHERN

ROAD Augusta(Richmond County),

Georgia

30901 Project # 030147 October 14, 2003 Testing conducted

for: Mr. David Johnson Environmental Manager Boral Bricks, Inc. (706) 849-5298

ANALYTICAL

TESTING

CONSULTANTS,

INC. 301 Brookdale

Street Karmapolis, N. C. 28083 (704) 932-3193

phone (800) 733-3193

toll-free (704) 932-0570

fax corp@atc-net.net e-mail www.atc-net.net Web page Distribution: Mr. David Johnson (Five copies) Issue Date: November 10, 2003TABLE OF CONTENTS Page Number IntroductionCertification of Results

........................... 3 Process Description

.................................... 4 Results Summary

...................................... 5 Results, Conclusions

and Comments 6 Sampling and Analytical

Procedures 7 ReferencesEmission Rate Calculations 10 Isokinetic Data and Calculations 13 Moisture Data

................................. 16 Isokinetic Sampling

Rate Calculation 17 Sample Calculations

................................... I8 Nomenclature

........................................ 20 Calculation Formulae

.................................. 22 Appendix I

.......................................... 25 Sampling Data Sheets 26 Stack Sketches

................................. 39 Enthalpy Analytical,

Inc. Lab Report 42 LELAP Certification 119 Analytical Testing Consultants,

Inc. Lab Report

129 LELAP Certification 154 Calibration Data 159

Page 2 of 171INTRODUCTION
This

report presents

the results of particulate/hydrogen fluoride/hydrogen

chloride

emissions testing conducted

on the scrubberYoaghouse

exhaust of the Plant 4 #1 Tunnel Kiln. Emissions sampling utilizing

US EPA methods

5/26a was performed

by Analytical

Testing Consultants, Inc. ofKannapolis,

NC. The three man test team consisted

of Dan McCombs,

Mike Stedwell and Kevin Adkins. Testing was completed

on Tuesday,

October

14, 2003. Ms. DeAnna

Oser of the Georgia Department of NaturaI Resources

witnessed

portions

of the sampling.

Mr. David Johnson

of Boral Bricks was on site during sampling

and was responsible

for collection

of process data. Three one-hour

runs were conducted

on the outlet of the baghouse. Executive Summary The test showed the HF and HC1 emissions

were below levels contained

in facility Part 70 operating permit (3251-245-0009-V-01-5) of 2.25 lbs per hour. Runs 1,2,3 averaged

0.264 lbs/hr particulate, 2.072 ibs/hr HF and 1.105 lbs/hr HC1.. Allowable

particulate

emissions

(are based upon total quantities

from the Clay Feed System Conveyor

Belts, Surge Bins, and the Tunnel Kiln #1 [Rule 391-3-1-.02(2)(e)].

The kiln average 9.28 tons per hour on October

14 th during the sampling.

CERTIFICATION OF RESULTS "By our signature

we certify that the testing and the reporting

of the test results contained

herein are prepared

to the best of our abilities and that, to our knowledge,

the data have been calculated

and reported correctly.

No data or information

has knowingly

been omitted."

W. Keith Poole Vice President/Technical

Director C. Daniel MeCombs President/Quality Manager
Page 3 of 171PROCESS DESCRIPTION
Belt conveyors

transport

prepared

clay form the Processed

Clay Storage Building

bays to Plant 4 [i.e. via the Clay Feed System Conveyors

(P4) (ID CB401)].

The materials

are conveyed

to Plant 4 where they feed the Plant 4 brick forming

line. The forming

line starts with a surge bin (]I) SB401) which feeds two (2) pug mills in series. Water may be added at the pug mills depending on the moisture

content of the clay. The "pugged"

clay then enters an extruder

and is formed as a column of brick. The column of brick may or may not be sand coated and textured

(SC 401), though typically

not. Once the column is coated/textured,

it is then cut into green bricks. Green brick are stacked onto kiln cars by a setting machine

and are placed in a holding

area where the moisture

content is lowered

slightly.

The kiln cars exit the holding

area directly into a set of Tunnel dryers for primary

drying.

The dryers are heated with waste heat from the cooling sections of the kiln. A pressure

differential

is maintained

within the kiln to prevent hot air and pollutants from entering

the kiln cooling section.

Therefore,

pollutant

emissions

from the dryer stacks are negligible. Finally, dried brick are moved directly

from the dryers into Tunnel Kiln #1 (EU401)

[Tunnel Kiln #2 (EU402)

is a proposed

future kiln]. The tunnel kiln is fueled by natural gas with propane as a backup fuel. Final evaporation

of free water, dehydration,

oxidation,

vitrification,

flashing, and cooling of bricks occurs in the kiln. Emissions

from the kiln are routed through

a single control device.

The control equipment

(CE401)

serves to reduce HF and HC1 emissions

from the kiln. Brick exiting the kiln are packaged

and moved to outside storage prior to distribution. The tunnel kiln control device-CE401-is

a Hydrated

lime Powdered

Injection

Scrubber

(w/ Venturi Reactor).

This serves to reduce the emissions

of HF and HC1 in the airstream

prior to release to atmosphere

through

the single 59.25' round, vertical

stack.

IProcess description provided

by Environmental Manager,

Boral

Bricks,

Inc.

David

Johnson, Page 4 of 171SYSTEM RESULTS

SUMMARY Born Bricks P4 Tunnel Kiln #1

TEST DATE

10/14/03 PARAMETER Run #1 Run #2 Run #3 GENERAL QS, FLOW, ACFM

44255

46614

45882 Q STD DRY, FLOWSCFM

33589

35426

33449 Vm STD (ft3)

37.08

38.61

37.40 %1 103.39

102.08

104.73
PARTICULATE EMISSIONS PMRc (lbs/hr)

0.336

0.255

0.201 Cs (GR/SCFD)

0.0012

0.0008

0.0007 ALLOWABLE (Ibs/hr) HCI EMISSIONS PMRc (Ibs/hr)

1.176

1.183

1.105 Cs (GR/SCFD)

0.0041

0.0039

0.0039 ALLOWABLE (Ibs/hr)
HF EMISSIONS PMRc (Ibs/hr)

1.871

2.089

2.255 Cs (GR/SCFD)

0.0065

0.0069

0.0079 ALLOWABLE (Ibs/hr) AVERAGE

45584 34155

0.264 0.0009

1,155 0.00392,250

2.072 0,00712,250

Page 5 of 171RESULTS, CONCLUSIONS AND COMMENTS

A summary

of some pertinent

results appear in the preceding

RESULTS

SUMMARY.

For additional information

please consult the CALCULATIONS

and DATA SHEETS

sections

of this report. Stack velocity,

as determined

by US EPA method

2, was calculated

based upon the differential pressure measurement

of the impact and static sides of a Stauschiebe

type pitot tube at twelve different points in each of the two test ports. The resultant

mean stack velocity

of 39.68 feet per second (ft/s) was multiplied

times the stack area of the test plane (19.15 ft 2) and by 60 (time conversion) to achieve a mean actual volumetric

flow rate of 45,554 cubic feet per minute (acfm). Prior to calculation

of the emission

rates, the ACFM value from each individual

run was adjusted to standard

conditions.

The mean standard

volumetric

flow rate was 34,155 scfm. Particulate emissions

were calculated

utilizing

the combined

net weights

of the filter catch and the residue from the front half rinse (nozzle, probe, cyclone bypass, and front half of filter assembly) and averaged

0.264 pounds

per hour (lbs/hr) with a concentration

of 0.0009s

per dry standard

cubic foot (gr/scfd).

There is no individual,

associated

particulate

allowable

for this source. Hydrogen Fluoride

concentrations

averaged

0.0173 micrograms

resulted

in a calculated emission rate of 0.046 lbs/hr. This average

is less than the allowable

of 2.25 lbs/hr. Hydrogen Chloride

concentrations

averaged

0.00963

micrograms

yielding

a calculated

emission rate of 1.155 lbs/hr. HC1 emissions

from the #1 Tunnel Kiln are required

to be no more than 2.25 lbs/hr. Ms. DeAnna

Oser of the State of Georgia

Department

of Natural Resources

requested

internal QA procedures

due to the very low reported

results from previous

testing.

A detailed

description of a Blind spike and a matrix spikes performed

for this request are reported

in the Enthalpy Analytical Narrative

Summary.

The Blind spike had a calculated

percent recovery

of 101% for the HF and 99.4% for the HC1.

Page 6 of 171SAMPLING AND ANALYTICAL

PROCEDURES Particulate/HC1/HF emissions

testing and analysis

were performed

according

to procedures developed by the U. S. Environmental

Protection

Agency

(USEPA)

and referred

to as Method 5/26A. Sampling

port locations

and number

of test points to be used were determined

according to Method

1 and are shown in the data sheets section of this report. The above federal test methods appear in the Code of Federal Regulations

(Reference

1). Test point locations

and sampling

port placement

for velocity

traverses

are shown in the data sheets. Test point locations

were calculated

based upon a 59.25" diameter,

round stack with 2 four inch test ports located ninety degrees apart. Twelve points were sampled

in each test port. An all glass US EPA method

5/26a sampling

train was utilized that employed

glass nozzles and probe liners. A glass filter assembly

held a Teflon filter frit with Teflon filter for determination

of particulate

emissions.

Connections

to the condenser train was a glass "double el" with a thermocouple

well for measurement

of exhaust temperature of the filter. The condenser

train consisted

of five glass impingers

connected sequentially. The first and second impingers

were charged

with 100 ml 0.1 N H2SO4, the third and fourth with 100 ml of 0.1 N H2SO 4. The fifth impinger

contained

300g of silica gel. All sample recovery

was conducted

on-site by Dan McCombs,

Mike Stedwell

and Kevin Adkins. Condenser train collections

were measured

and rinsed into pre-labeled

amber glass jars. The sulfuric acid fractions

were forwarded

to Enthalpy

Analytical,

Inc. a LELAP

accredited laboratory (Certificate

No. 04010, agency interest no. 85848).

A copy of Enthalpy's accreditation is included

in Appendix

I. for determinations

of HC1/HF

via US EPA 26a. The sodium hydroxide

fractions

were discarded. The front half of the sampling

train was rinsed with reagent grade acetone

and stored in 500 ml Nalgene® bottles and transported

to ATC for analysis.

Liquid levels were marked on the sampling bottles with a marker.

Particulate

analysis

was completed

Analytical

Testing Consultants, Inc., a LELAP

accredited

laboratory

(Certificate

No. 04044) A blank of the acetone reagent was collected

in the field, along with the field samples

and analyzed side by side. According

to standard

practices

and the QA/QC handbook

EPA-600/4-94- 038c, acetone blanks should not be subtracted

over 0.001%.

The acetone residue of 0.0005 was well under the maximum

allowable

residue of0.0011.

Corrections

are show in the particulate lab report.

Page 7 of 171REFERENCES

1.

CODE OF FEDERAL

•GULATIONS,

Title 40, Part 60, Appendix

A, July 1, 2001.

Page 8 of 171ISOKINETIC DATA

AND CALCULATIONS
Emission Rate Calculations Particulate HC1HF Isoldnetic Data and Calculation Moisture Data Isokinetic Sampling

Rate Data Sample Calculations Nomenclature Calculation Formulae

Page 9 of 171PARTICULATE EMISSION

RATE

CALCULATION
L OCA TION: Bora/Bricks SOURCE: P4 Tunnel Ki/n #1 DATA DATE RUN TIME (min) gn (in) An (ft •) A VG DH (in H20) P A TM (in Hg) Pm (in Hg) Ps (GAUGE) Ps (IN HG) Tm (F) Tm (R) Vm (ft3) Vm STD (ft3) VLQ (mO VV STD (ft3) V STD (ft3)%MMD MWDMTs(OTs(R) SUM SQRT DP N DP A VG SQRT DPCP Vs (•s) Ds (in) As (ft2) QS, FLOW, ACFM Q STD (ft3/min) Q STD DRY, FLOW SCFM WT (gm)%1 %C02%02%C0%N2 PMRc (Ibs/hr) Cs (GR/SCFD)

Run #1 Run #2 Run #3 AVERAGE 10/14/03 10/14/03

10/14/03 60.00 60.00

60.00 0.250 0.250

0.250 3.41E-04 3.41E-04

3.41E-04 1.16 1.28

1.22 29.88 29.88

29.88 29.99 29.97

29.97 -0.25 -0.25

-0.25 29.86 29.86

29.86 75.58 78.46

81.04 535.25 538.13

540.71 37.39 39.16

38.12 37.08 38.61

37.40 30.50 29.50

62.50 1.44 1.39

2.95 38.51 40.00

40.34 3.73 3.48

7.31

4.84 0.963 0.965

0.927 29.00 29.02

29.03 28.59 28.63

28.22 208.71 209.63

210.38

209.57 668.38 669.30

670.05

669.24 14.55 15.33

14.97 24.00 24.00

24.00 0.61 0.64

0.62 0.84 0.84

0.84 38.52 40.58

39.94

39.68 59.25 59.25

59.25 19.15 19.15

19.15 44255 46614

45882

45584 34892 36702

36085

35893 33589 35426

33449

34155 0.0028 0,0021

0.0017 103.39 10.2.08

104.73 1.50 1.64

1.75

1o63 19.08 18.88

18.75

18.91 0.00 0.00

0.00 79.42 79.48

79.50 0.336 ,0.255

j0.201

0.264 0.0012 0.0008

0.0007

0.0009

Page 10 of 171HC! EMISSION

RATE

CALCULATION
LOCA T/ON: Bora/ Bricks SOURCE: P4 Tunne/ Ki/n #1
DATA Run #1 Run #2 Run #3 AVERAGE DA TE

10/14/03

10/14/03

10/14/03 RUN TIME (min)

60.00

60.00

60.00 Dn (in)

0.250

0.250

0.250 An (ft a) 3.41E-04

3.41E-04

3.41E-04 AVG DH (in H20)

1.16

1.28

1.22 P A TM (in Hg)

29.88

29.88

29.88 Pm (in Hg)

29.99

29.97

29.97 Ps (GAUGE)

-0.25

-0.25

-0.25 Ps (IN HG)

29.86

29.86

29.86 Tm (F)

75.58

78.46

81.04 Tm (R)

535.25

538.13

540.71 Vm (ft3)

37.39

39.16

38.12 Vm STD (ft3)

37.08

38.61

37.40 VLQ (ml)

30.50

29.50

62.50 VV STD (ft3)

1.44

1.39

2.95 V STD (ft3)

38,51

40.00

40.34 %M 3.73

3.48

7.31

4.84 MD 0.963

0.965

0.927 MWD 29.00

29.02

29.03 M 28.59

28.63

28.22 Ts (F)

208.71

209.63

210.38

209.57 Ts (R)

668.38

669.30

670.05

669.24 SUM SQRT DP

14.55

15.33

14.97 N DP

24.00

24.00

24.00 AVG SQRT DP

0.61

0.64

0.62 CP 0.84

0.84

0.84 Vs (ft/s)

38.52

40.58

39.94

39.68 Ds (in)

59.25

59.25

59.25 As(ft2) 19.15

19.15

19.15 QS, FLOW, ACFM

44255

46614

45882

45584 Q STD (ft3/min)

34892

36702

36085

35893 Q STD DRY, FLOW SCFM

33589

35426

33449

34155 WT (gm)

9.81E-03

9.74E-03

9.34E-03 %i 103.39

102.08

104.73 %C02 1,50

1.64

1.75

1.63 %02 19.08

18.88

18.75

18.91 %C0 0.00

0.00

0.00 %N2 79.42

79.48

79.50 PMRc(Ibs/hr) ,1.176

,1.183

,1.105

1.t55 Cs (GR/SCFD)

0.0041

0.0039

0.0039

0.0039

Page 11 of 171HF EMISSION

RATE

CALCULATION

L OCA TiON: Bora/Bricks SOURCE: P4 Tunne/ Ki/n #1 DATA Run #1 Run #2 Run #3 DATE 10/14/03

10/14/03

10/14/03 RUN TIME (rain)

60.00

60.00

60.00 Dn (in)

0.250

0.250

0.250 An (ft •) 3.41E-04

3.41E-04

3.41E-04 A VG DH (in H20)

1.16

1.28

1.22 P A TM (in Hg)

29.88

29.88

29.88 Pm (in Hg)

29.99

29.97

29.97 Ps (GAUGE)

-0.25

-0.25

-0.25 Ps (IN HG)

29.86

29.86

29.86 Tm (F)

75.58

78.46

81.04 Tm (R)

535.25

538.13

540,71 Vm (ft3)

37.39

39.16

38.12 Vm STD (ft3)

37.08

38.61

37.40 VLQ (ml)

30.50

29.50

62.50 VV STD (ft3)

1.44

1.39

2.95 V STD (ft3)

38.51

40.00

40.34 %M 3.73

3.48

7.31 MD 0.963

0.965

0.927 MWD 29.00

29.02

29.03 M 28.59

28.63

28.22 Ts (F)

208.71

209.63

210.38 Ts (R)

668.38

669.30

670.05 SUM SQRT DP

14.55

15.33

14.97 N DP

24.00

24.00

24.00 A VG SQRT DP

0.61

0.64

0.62 CP 0.84

0.84

0.84 Vs (fEs)

38.52

40.58

39.94 Ds (in)

59.25

59.25

59.25 As(ft2) 19.15

19.15

19.15 QS, FLOW, ACFM

-44255

,46614

'45882 Q STD (ft3/min)

34892

36702

36085 Q STD DRY, FLOW SCFM

33589

35426

33449 WT (gm)

1.56E-02

1.72E-02

1.91 E-02 %1 103.39

102.08

104.73 %C02 1,50

1,64

1.75 %02 ,19.08

18.88

18.75 %C0 0.00

0.00

0.00 %N2 79.42

79.48

79.50 PMRc (lbs/hr)

1.871

2.089

2.255 Cs (GR/SCFD)

0.0065

0.0069

0.0079

A VERA GE

4.84

209.57 669.24

39.68

45584 35893 34155

1.6318.91

2.072 0.0071

Page 12 of 171DATE SOURCE ISOKINETIC

DATA

AND CALCULATIONS 10/14/03 P4 Tunnel Kiln #1 Run #1 K= 3.1489067 POINT #

Tm

Ts

dp

dH SQRT DP

% 02 A1 72

207

0.330

1.04

0.574

19.2 A2 72

207

0.350

1,10

0.592 A3 73

208

0.380

1.20

0,616

19.3 A4 73

209

0.390

1.23

0.624 A5 73

210

0.390

1.23

0.624

19.1 A 6

74

210

0.360

1.13

0.600 A7 75

211

0.340

1.07

0.583

19 A8 75

212

0.320

1.01

0.566 A9 75

212

0.310

0.98

0.557

19.3 A 10

75

212

0.300

0,94

0,548 All 76

211

0.300

0.94

0.548

19.2 A12 76

208

0.290

0.91

0.539 B 1

76

207

0.400

1.26

0.632

19.2 B2 76

207

0.430

1.35

0.656 B3 76

207

0.440

1.39

0.663

19.3 B4 76

207

0.450

1.42

0.671 B5 77

206

0.450

1.42

0.671

19 B6 77

206

0.450

1,42

0.671 B7 77

206

0.390

1.23

0.624

19.2 B8 78

207

0.360

1.13

0.600 B9 78

209

0.360

1.13

0.600

19 BIO 78

210

0,360

1.13

0.600 Bll 78

211

0.360

1.13

0,600

19.3 B12 78

209

0.350

1.10

0.592 75.58 Vm(ft3) 208.71 InitialFinalTotal 1.16

14.551

19.18 corrected per 6C-1

19.08 14.15 % N2 (BY DIFFERENCEJ 51.54 3 7.39

%Excess

Air

Calibration Actual Gas Zer_.__Qo 0.0 Mid-Range 10.6 • 19.0

Calibration

Data Instrument Reading Pre- -Post

Pre0.0 0 0.00 10.6 10.6

0.24 19.1 n/a 0.48 Based upon 2% of span value (21%) % Error* %C021.51.51.51.51.51.51.51.51.51.51.51.5
1.50 79.42 1014.53

-Post0.000.24n/a

Page 13 of 171DATE SOURCE Run #2 POINT #

ISOKINETIC

DATA

AND CALCULATIONS 1 O/14/03 P4 Tunnel Kiln #1

K=

3.116 Tm Ts

dp

dH SQRT DP

% 02 A1 77

211

0.450

1.40

0.671

19 A2 77

212

0.460

1.43

0.678 A3 77

211

0.470

1.46

0.686

19.2 A4 77

211

0.470

1.46

0.686 A5 78

211

0.480

1.50

0.693

19.3 A6 77

2t0

0.460

1.43

0.678 A7 78

210

0.440

1.37

0.663

19.2 A8 78

209

0.390

1.22

0.624 A9 78

208

0.370

1.15

0.608

19.3 AIO 78

207

0.350

1.09

0,592 A 11

78

205

0.350

1.09

0.592

19.1 A 12

78

201

0,310

0,97

0.557 B1 78

205

0.440

1.37

0.663

18,7 B2 79

208

0.450

1.40

0.671 B3 79

210

0.450

1,40

0.671

18.9 B4 79

211

0.450

1.40

0.671 B5 79

212

0.470

1,46

0.686

18.7 B 6

79

212

0.460

1.43

0.678 B7 80

213

0,390

1.22

0.624

19.1 B8 79

213

0.370

1.15

0.608 B9 80

213

0.370

1.15

0.608

19.2 B 10

80

213

0.370

1.15

0.608 Bll 80

212

0,350

1.09

0.592 B12 80

203

0.270

0.84

0.520 % C021.51.51.51.51.51.52221.51.5

78.46 Vm(ft3) 209.63 InitialFinalTotal 1.28

1&327

19.06 correctedper6C.1 1&88 51,67 %N2(BYDIFFERENCEJ 90.833•16 %ExcessA• 1.6479.48 900.20
Calibration Actual Gas Zer.•..9o 0.0 Mid-Range 10.6 • 19.0

Calibration

Data Instrument Reading

% Error* Pre- -Post

Pre-

-Post 0.0 0 0.00

0.00 10.6 10.7

0.24

0.71 n/a n/a n/a

n/a Based upon 2% of span value (21%)

Page 14 of 171DATE SOURCE ISOKINETIC

DATA

AND CALCULATIONS 10/14/O3 P4 Tunnel Kiln #1 Run#3

K= 3.125219 POINT #

Tm

Ts

dp

dH SQRT DP

% 02 A 1

80

205

0.380

1.19

0.616

18.4 A2 80

204

0.390

1.22

0.624 A3 80

205

0.410

1.28

0.640

18.8 A4 80

205

0.430

1.34

0.656 A5 80

207

0.420

1.31

0.648

18.8 A6 80

209

0,390

1.22

0.624 A7 81

210

0.420

1.31

0.648

19.2 A8 81

212

0.410

1.28

0.640 A9 81

213

0.380

1.19

0,616

19.3 A 10

81

213

0.360

1.13

0.600 All 81

213

0.350

1.09

0.592

19.4 A12 81

208

0.290

0.91

0.539 B1 81

210

0.380

1.19

0.616

19.1 B2 81

213

0.410

1.28

0.640 B3 81

213

0.420

1.31

0.648

19.2 B4 81

213

0.430

1,34

0.656 B5 81

214

0.430

1.34

0.656

18.8 B6 82

214

0,440

1.38

0.663 B7 82

213

0.400

1.25

0,632

18.7 B8 82

213

0.390

1.22

0.624 B9 82

213

0.380

1.19

0.616

18,6 BIO 82

212

0.380

1.19

0.616 Bll 82

211

0.370

1,16

0.608

18.8 B12 82

206

0.300

0.94

0.548 81.04 Vm(ft3) 210.38 InitialFinalTotal 1.22

14.970

18.93 corrected per 6C- 1 18. 75 90.97 % N2 (BY DIFFERENCEJ 129.0938.12 % Excess A ir

Calibration Actual Gas Zer...__qo 0.0 Mid-Range 10.6 Hi-Ran_•e 19.0

Calibration

Data Instrument Reading

% Error* Pre- -Post

Pre-

-Post 0.0 0 0.00

0.00 10.7 10.6

0,71

0.24 n/a n/a n/a

n/a Based upon 2% of span value (21%) % C022221.51.5

1,51,52222
1.7579.50 836.41

Page 15 of 171MOISTURE DATA

Run #1 BEGINNING ENDINGNET

lstlmp.

2ndlmp.

3rd& 4•. 5• Imp. TOTALS 100.00 100.00

200.00

300.00 112.00 111.00

198.00

309.50 12.00 11.00

-2.00

9.50

30.5
Run #2 BEGINNING ENDINGNET

Run #3 BEGINNING ENDINGNET

lstlmp.

2ndlmp.

3rd& 4•. 5• Imp. TOTALS 100.00 100.00

200.00

300.00 110.00 112.00

198.00

309.50 10.00 12.00

-2.00

9.50

29,5 lstlmp. 2ndlmp.

3rd& 4•. 5• Imp. TOTALS 100.00 100.00

200.00

300.00 122.00 116.00

215,00

309.50 22.00 16.00

15.00

9.50

62.5

Page 16 of 171ISOKiNETIC SAMPLING

RATE

CALCULATION dH KdP K (846.72*Dn^4*dH@*Cp^2*(1-Bw)^2*Md*Tm*Ps)/(Ms*Ts*Pm)
Run #1 Run #2 Run #3 Dn 0.250

0.250

0.250 dH@ 1.78

1.78

1.78 Y, gamma factor

1.00

1.00

1.00 Cp 0.84

0.84

0.84 Bw(FRACTION, NOT%)

0.05

0.05

0.05 Md 29.00

29.00

29.00 Pbar 29.88

29.88

29.88 PS (GAUGE)

-0.25

-0.25

-0.25 Ps 29.86

29.86

29.86 Tm, F

85.00

85.00

85.00 Tm, R

544.67

544.67

544.67 Ms 28.45

28.45

28.45 Ts, F

200.00

207.00

205.00 Ts, R

659.67

666.67

664.67 Pm 29.99

29.99

29.99 K 3.1489

3.1158

3.1252 TERMINOLOGY Ms=APPARENT STACK GAS MOLECULAR

WEIGHT =Md(1-Bw)+18Bw Md=DRY GAS MOLECULAR

WEIGHT

(29) OR =(0.44*%CO2)+(0.32*%O2)+(0.28*(%N2+%CO)) Ps GAUGE=STACK

STATIC PRESSURE

(IN. H20) Ps=ABSOLUTE STACK PRESSURE

(IN. Hg) Pm=METER ABSOLUTE

PRESSURE

(IN. Hg) Pbar + (avg dH/13.6)

Page 17 of 171SAMPLE CAL CULA TIONS Borai Bricks Augusta, GA Run #1 1) ABSOLUTE

PRESSURE

IN DRY GAS METER Pm P ATM + AVG DH/13,6
P ATM

Avg. DH 29.88 1.16 2) ABSOLUTE

STACK PRESSURE Ps P ATM + Ps(GAUGE)/13.6

Pm29.97

P ATM Ps(GAUGE)

Ps 29.88 -0.25

29.86 3) SAMPLE VOLUME AT STANDARD

CONDITIONS VM STD (VM)*(Y)*(T

STDfI'M)*(PM/P

STD)
Vm Tm

Y

Vm STD 1.003 37.05

ft3 37.39 535.25 T STD P STD

4) VOLUME OF WATER COLLECTED,

CORRECTED

TO STANDARD

CONDITIONS VV STD W STDw + WSTDsg
W STDw (.002673)*(VLQw)*(T

STD/P STD) W STDsg (.002668)*VLQsg)*(T

STD/P STD)
WHERE 0.002673

0.04707 FT3/ML*IN.

HG/17,64 DEG. R. WHERE 0.002668

0.04715 FT3/G*IN.HG/17.64

DEG. R. VLQ (w) VLQ (sg)

W STD 21.00 9.50

1.44 ft3 5) TOTAL SAMPLE VOLUME AT STANDARD

CONDITIONS V STD Vm STD + W STD 38.48 ft3

3.74%

0,963 6) PERCENT

MOISTURE

IN STACK GAS %M (100)*(W STD)/V STD 7) MOLE FRACTION

OF DRY GAS MD (100-%M)/100 528 DEG R, 29.92 IN. HG

Page 18 of 171SAMPLE CALCULATIONS
7A) MOLECULAR

WEIGHT OF THE DRY GAS
MWD (%CO2*0.44)+(O2*0.32)+((%CO+%N2)*0.28) %CO2 %02

%CO

%N2

MWD 1.50 19.08

0.00

79.42

29.00 8) MOLECULAR

WEIGHT OF THE WET GAS M (MWD)*(MD)

+ 18(1-MD) 28.59
WHERE 18 MOLECULAR

WEIGHT OF WATER, G/G-MOLE 9) STACK VELOCITY VS (85.49)*(CP)*((TS/(PS)(M))^l/2*((SUM SQRT DP)/N DP)) where 85.49 ft/sec* [Ib/Ib-mole*in.Hg)/(deg.

R'in H20)]^0.5
CP Ts (R) SUM SQRT

N DP VS 0.84 668.38

14.55

24 38.52 10) STACK VOLUMETRIC

FLOW RATE QS (60)*(VS)*(AS)
AS (inlet) QS 19.15 44255 11) STACK VOLUMETRIC

FLOW RATE, STANDARD

CONDITIONS

INCLUDING

MOISTURE Q STD Q STD DRY/MD 34892 12) STACK VOLUME FLOW RATE STANDARD

CONDITIONS

DRY Q STD DRY= 17.647*60*Md*Vs*A*(PsFFs(R)) 33588 13) POLLUTANT

MASS RATE, CONCENTRATION

BASIS PMRC (.1323)*(WT)*(Q

STD)N STD WHERE 0.1323 COMBINED

CONVERSION

FACTOR (60 MIN/HR*0.00220

LBS/GRAM) WT(GRAMS) PMRC 0.0028 0.336 14) PERCENT

ISOKINETIC %1 (0.09450*Ts*Vrn

std)/(Ps*Vs*An*Time*Md) Run Time Area of Nozzle 60 3.41E-04 %1 103.31 15) CONCENTRATION,

GPJSCFD Cs= 15.43 gr/gm WTNm STD Cs 0.0012

Page 19 of 171