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, 2003 
TABLE OF CONTENTS 

Page 

Number 

Introduction 

Certification of Results ........................... 3 

Process Description .................................... 4 

Results Summary ...................................... 5 

Results, Conclusions and Comments 6 

Sampling and Analytical Procedures 7 

References 

Emission 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 171 
INTRODUCTION 

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 171 
PROCESS 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 171 
SYSTEM 

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 

0.0039 

2,250 

2.072 

0,0071 

2,250 

Page 5 of 171 
RESULTS, 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 171 
SAMPLING 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 171 
REFERENCES 

1. CODE OF FEDERAL •GULATIONS, Title 40, Part 60, Appendix A, July 1, 2001. 

Page 8 of 171 
ISOKINETIC DATA AND CALCULATIONS 

Emission Rate Calculations 

Particulate 

HC1 

HF 

Isoldnetic Data and Calculation 

Moisture Data 

Isokinetic Sampling Rate Data 

Sample Calculations 

Nomenclature 

Calculation Formulae 

Page 9 of 171 
PARTICULATE 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) 

%M 

MD 

MWD 

M 

Ts(O 

Ts(R) 

SUM SQRT DP 

N DP 

A VG SQRT DP 

CP 

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 171 
HC! 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 171 
HF 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 

1.63 

18.91 

2.072 

0.0071 

Page 12 of 171 
DATE 

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 

Initial 

Final 

Total 

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* 

%C02 

1.5 

1.5 

1.5 

1.5 

1.5 

1.5 

1.5 

1.5 

1.5 

1.5 

1.5 

1.5 

1.50 

79.42 

1014.53 

-Post 

0.00 

0.24 

n/a 

Page 13 of 171 
DATE 

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 

% C02 

1.5 

1.5 

1.5 

1.5 

1.5 

1.5 

2 

2 

2 

1.5 

1.5 

78.46 

Vm(ft3) 

209.63 

Initial 

Final 

Total 

1.28 1&327 19.06 

correctedper6C.1 1&88 

51,67 %N2(BYDIFFERENCEJ 

90.83 

3•16 %ExcessA• 

1.64 

79.48 

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 171 
DATE 

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 

Initial 

Final 

Total 

1.22 14.970 18.93 

corrected per 6C- 1 18. 75 

90.97 % N2 (BY DIFFERENCEJ 

129.09 

38.12 % 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%) 

% C02 

2 

2 

2 

1.5 

1.5 

1,5 

1,5 

2 

2 

2 

2 

1.75 

79.50 

836.41 

Page 15 of 171 
MOISTURE DATA 

Run #1 

BEGINNING 

ENDING 

NET 

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 

ENDING 

NET 

Run #3 

BEGINNING 

ENDING 

NET 

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 171 
ISOKiNETIC 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 171 
SAMPLE 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 

Pm 

29.97 

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 

37.39 535.25 1.003 37.05 ft3 

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 171 
SAMPLE 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