I!/ll•i zooo 

Bowerston Shale Company 

515 Main Street 

Bowerston, Ohio 44695 

Report 

Performed Velocity, Temperature, Moisture, Particulate and ltydroflourc Acid Emission Determinations 

Sampling at Source P003 Exhaust 

Bowerston, OH. 

Test Date: 11/16/00 
Bowerston Shale Company 

515 Main Street 

Bowerston, Ohio 44695 

Report 

Performed Velocity, Temperature, Moisture, 

Particulate and Hydroflouric Acid Emissions Testing 

Sampling at Source P003 Exhaust 

Bowerston, OH. 

Test Date: 11/16/00 

•;'•mes K. Gray 

Custom Stack Analysis, LLC. 
TABLE OF CONTENTS 

Executive Summary 

Methods Description 

Sampling Train Diagram 

Sampling Point Description 

Calculations .................................................................. 

APPENDIX 

Test Data 1 

Laboratory Data 2 

Calibration Data 3 

Production Data 4 

1 

2-3 

4 

5 

6-9 

Custom 8tackAnaly•is, I-,LC. P, O. Box 37.•0 24385 Center Road Alliance, Ohio 44601 Phone: 330-525-$119 Fax: 330-.•25-7908 E-mail: customstacla•voyager.net 
EXECUTIVE SUMMARY 

Custom Stack Analysis, LLC. conducted emissions sampling using Methods 1-4, 26A. 

Testing was conducted at Kiln #3 exhaust. This testing was conducted on November 16, 2000, 

for compliance demonstration. The Custom Stack Analysis, LLC. test crew consisted of Mr. 

James Gray and Mr. Greg Thayer. The testing procedures were coordinated by Mr. Ed Milliken 

of Bowerston Shale Company. Testing procedures were witnessed by Ms. Kay Gilmer and Mr. 

Ralph Witte of the Ohio EPA Southeast District Office. 

A description of the testing protocal is included on pages 2-3. All testing calculations 

are located on pages 6-9. Appendix 1 includes field test data sheets. Appendix 2 contains 

laboratory data from Custom Stack Analysis, LLC and Data Analysis Technologies, Inc. 

Appendix 3 contains calibration data for equipment used on test day. Appendix 4 is production data from Bowerston Shale Company.Test results are as follows: 

OUTLET 

Run #1 Run #2 Run #3 AVG 

Stack Gas Velocity (ft/sec) 37.55 38.03 37.58 

Standard cubic feet an hour 441,767 444,876 440,261 

Actual cubic feet per minute 12,571 12,731 12,580 

Moisture % 7.23 % 7.42 % 7.76 % 

Isokinicity % 100.68 % 99.91% 100.19 % 

Particulate (lbs/hr) .28 .34 .42 .35 

Particulate (grains/dscf) .00444 .00526 .00673 .00547 

Particulate (Ibs/dscf) 6.36236 E-07 7.534578 E-07 9.642714 E-07 7.8465 E-07 

Hydroflouric Acid (Ibs/hr) 1.63 1.65 1.6 1.63 

Hydroflouric Acid (PPM) 39 39 38 39 

Hydroflouric Acid (PPM @ 7% oxygen) 106.5 97.7 121.4 108.5 

Custom Stack Analy•, LLC. P. O. Box 3750 24385 Center Rood Alliance, Ohio 44501 Phone: 330-525-5119 Fax: 330-525-7908 E-moil: customstack•voyager.net 

Page 1 
ME'J'HOD 1 

Sample and velocity traverses for stationary sources. 

To aid in the representative measurement of pollutant emissions and/or total volumetric 

flov• rate from a stationary source, a measurement site •vhere the effluent stream is flowing in 

a known direction is selected, and the cross-section of the stack is divided into a number of 

equal areas. A traverse point is then located within each of these equal areas. 

METHOD 2 

Determination of stack gas velocity and volumetric flow rate. 

The average gas velocity in a stack is determined from the gas density and from 

measurement of the average velocity head with a Type S (Stausscheibe or reverse type) pitot 

tube. 

METHOD 3 

Gas analysis for the determination of dry molecular weight. 

This method is applicable for determining carbon dioxide and oxygen concentrations 

and dry molecular weight of a sample from a gas stream of a fossil-fuel combustion process. 

METHOD 4 

Determination of moisture content in stack gases. 

A gas sample is extracted at a constant rate from the source. It is determined either 

volumetrically or gravimetrically. 

Custom StackAnalysis, LLC. P. O. Box 3750 24385 Center Road Alliance, Ohio 44601 Phone: 330-525-5119 Fax: 330-525-7908 E-mail: customstacl@oyager.net 

Page 2 
METHOD 26A TE•TING DESCRIPTION 

Samples were collected following EPA Method 26A. Each point was sampled for 5 

minutes for a total of a 60 minute test. Three 60 minute tests were performed. The equipment 

used for testing consisted of a Burrell Model B orsat analyzer and a Alliance Pollution Control 

Sampling Apparatus (EPA type). A type "S" pitot and a heated sampling probe was used with 

the sampling train. All equipment was calibrated in the laboratory prior to the test. The 

sampling nozzle and the pitot tubes were measured on the day of the test. All calibrations can 

be found in the appendix. The gases are passed through a heated pyrex probe and a heated 

glass four inch filter holder containing Pallflex TX40HI45 filter media. The gases leaving the 

filter were collected in a series of six impingers packed in ice. The first, second and third 

impinger shall be of the Greensburg-Smith design with a standard tip. The first two impingers 

contained 100 ml of 0.1 N H2SO4. The next impinger contained 100 ml of 0.1 N NaoH and the 

last impinger was left empty. After passing through the fourth impinger the gases pass through 

a "Drierite" column containing about 500 grams of calcium sulfate (CaSO4) desicant to 

remove the remaining water vapor. The dry gas then passed through the hose portion of.the 

umbilical cord to a Alliance Pollution Control stack sampling module. In the module the gas 

was moved through the system by a leakless air pump to a Rockwell 175-S dry test meter. 

The dry test meter exhausted to a calibrated orifice to measure the flow rate of the gases 

passing through the sampling apparatus. A type "S" pitot tube Was attached to the sheath of 

the heated probe and nozzle. The orifice pressure taps and the pitot tube were connected to a 

Dwyer dual 10 inch combination inclined-well type manometer. One half of the manometer 

measured the orifice differential pressure (^H) and the other half measured the flue gas 

velocity head (^P). The temperature of the flue gas was measured by a type "K" thermocouple 

connected to a Marlin Digital Temperature Indicator. The C02 and 02 levels were determined 

using a Burrell "Industrial Model B orsat analyzer. 

Custom Stack Analysis, LLC P. O. Box 3750 24385 Center Road Alliance, Ohio 44601 Phone: 330-525-5119 Fax: 330-525-7908 E-mail: customstacl•voyager.net 

Page 3 
R•OD 26A SAMPLING APPARATUS 

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Page 4 1 
Location Of Sampling Points 

Traverse Locations 

Location Outlet 

Upstream 2 dia. 

Downstream 6 dia. 

Stack Diameter 

Port 

Upstream 

32 inches 

Downstream 

Sample Point # 

1 1.4 

2 4.7 

3 9.5 

4 22.5 

5 27.3 

6 30.6 

inches 

CustomStack Analysis, ZZC P. O. Box 3750 24385 Center Road .,Jlliance, Ohio 44601 Phone: 330-525-5! 19 Fax: 330-525-7908 E-mail: customstack•oyager.net 

Page 5 
CALCULATIONS 

Outlet 

RUN #1. RUN #2. RUN #3. 

Vm (std) 53°03 52•38 51.22 

^H 

VM 17.64" PBAR + 13.6 Y 

Tm 

Vm (std) Volume of gas collected, corrected to standard conditions, cuft. 

Vm Volume of gas sampled at meter box, cuft. 

RUN #1 RUN #2 RUN #3 

53.03 52.38 51.22 

53.69 53.24 52.35 

17.64 17.64 17.64 

534.00 536.00 539.00 

29.86 29.86 29.86 

2.600 2.600 2.550 

13.60 13.60 13.60 

1.001 1.001 1.001 

17.64 

Tm 

Standard temperature, 528 Rankine / std pressure, 29.92. 

Average dry gas meter temperature, + 460 Rankine. 

Pbar 

^H 

Barometric pressure, inches of mercury (Hg) 

Average pressure differential across orifice. 

13.6 

Y 

Specific gravity of mercury. 

Calibration factor of meter box. 

RUN #1. RUN #2 RUN #3 

Vw (std) 4.13 4.20 4.35 Vlc PH20 RTstd K2 Vlc 

Mh20 Pstd 

RUN #1 RUN #2. VIc Volume of water and silica colected. 87.80 89.20 92.50 

P H20 Density of water, 0.002201 Ib/ml. 0.002201 0.002201 0.002201 

M H20 Molecular weight of water, 18.01 Ib/Ib-mole. 18.01 18.01 18.01 

R Ideal gas constant, 21.85 in. hg ft3/R-Ib-mole. 21.85 21.85 21.85 

Tstd Standard absolute temperature, 528 R. 528.00 528.00 528100 

Pstd Standard absolute pressure, 29.92 in. Hg. 29.92 29.92 29.92 

K2 0.0471 ft3 ml. 0.0471 0.0471 0.0471 

RUN #3 

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Page 6 
3= 

RUN #1_ RUN #2 RUN #3 

Bws 0.0723 0.0742 0.0783 Vw(std) 

Vm(std) + Vw(std) 

RUN #1 .c RUN #2. 

Bws Water vapor in the gas stream, proportion. 0.0723 0.0742 

Vw(std) Volume of water vapor in the gas sample, scf. 4.13 4.20 

Vm(std) Volume of gas sampled at meter box, scf. 53.03 52.38 

RUN #3 

0.0783 

4.35 

51.22 

4o 

RUN #1 RUN #2 RUN #3 

Md 29.24 29.32 29.17 !0.44(%CO2) + 0.32(%02) + 0.28 (%N2) + %CO) 

RUN #1 RUN #2 RUN #3. Md Dry molecular weight, Ib Ib-mole. 29.24 29.32 29.17 

0.44 Molecular weight of CO2 divided by 100. 0.44 0.44 0.44 

0.32 Molecular weight of 02 divided by 100. 0.32 0.32 0.32 

0.28 Molecular weight of N2 or CO divided by 100. 0.28 0.28 0.28 

Co2, 02, N2, and CO are in percent by volume, dry basis. 

RUN #1 RUN #2 RUN #3. 

Ms 28.43 28.48 28.30 Md (1-Bws) + MH20 (Bws) 

RUN #1. RUN #2_ RUN #3 

Ms Molecular weight of gas, wet basis, Ib/Ib-mole. 28.43 28.48 28.30 

M H20 Molecular weight of water, 18 Ib ! Ib-mole. 18.00 18.00 18.00 

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Page 7 
Ms 

RUN #t RUN #2 RUN #3 

37.55 38.03 37.58 ]85.49 "Gp •V•--'p •_Ts +4601 

Vs Average stack gas velocity, ft sec: --• RUN #1 RUN #2_ RUN #3 

37.55 38.03 37.58 

85.49 Pitot tube constant, ff sec. 85.49 85.49 85.49 

Cp Pitot tube coefficient, dimensionless. 0.84 0.84 0.84 

^P Velocity head of stack gas, avg. sq rt. 0.53 0.53 0.53 

Ts Temperature of stack gas, + 460 (Rankine). 838.00 841.00 836.00 

Ps Absolute stack gas pressure, barometric + static. 29.87 29.87 29.87 

Ms Molecular weight of stack gas, wet basis. 28.43 28.48 28.30 

RUN #1 RUN #2 RUN #:3 

ACFM 12571 12731 12580 Stack Area 60 Vs 

RUN #1 RUN #2 RUN #3 

Vs Average stack gas velocity, ftJ sec. 37.55 38.03 37.58 

RUN #1 RUN #2_ R__UN #3_ 

K4 Ts Vm(std) Isokinicity 100.68 99.91 99.29 .Ps Vs An Min •(1-Bwsi 

RUN #1 RUN #2_ RUN #3 

K4 0.09450 for English units. 0.09 0.09 0.09 

Ts Stack temperature + 460 R. 838.00 841.00 836.00 

Vm(std) Volume of gas collected, scf. 53.03 52.38 51.22 

Ps Stack pressure, inches Hg. 29.87 29.87 29.87 

Vs Stack velocity, ft sec. 37.55 38.03 37.58 

An Area of the sampling nozzle, cuff. 0.0006679 0.0006605 0.0006563 

Min. Minutes of test 60.00 60.00 60.00 

Bws Water vapor in the gas stream, proportion. 0.0723 0.0742 0.0783 

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Page 8 
RUN #1 

9. Lbs/Hr 0.28 

2.205 E-6 

Mn' 

scfh 

Vm std 

RUN #2 RUN #3 

0.34 0.42 2.205 

Conversion from mg to Ibs. 

Weight gain of filter and wash minus blank. 

Standard stack volumetric flow rate. 

Volume of air sampled at stp. 

MR 

Eo6 

Vm std 

scfh 

RUN #1 RUN #2 RUN #3. 

2.205 E- 2.205 E-6 2.205 E-6 

15.30 17.90 22.40 

441767.00 444876.00 440261.00 

53.03 52.38 51.22 

10. Gr/Dscf 

RUN #1 RUN #2 RUN #3 

0.00444 0.00526 0.00673 

0.0154 

Vm std 

Mn 

Conversion to grains from mg. 

Volume of air sampled at stp. 

Weight gain of filter and wash minus blank. 

Mn 

,0.0154 

Vmstd 

RUN #1 RUN #2 RUN #3 

0.0154 0.0154 0.0154 

53.03 52.38 51.22 

15.30 17.90 22.40 

11. SCFH 

RUN #1 RUN #2 RUN #3. 

441767.00 444876.oo 440261.00 

3600 

Bws 

A 

Tstd 

Pstd 

Ts 

Ps 

Ms 

i3600 (1 Bws Vs A 

Ts Pstd 

RUN #1 RUN #2 RUN #3 

Seconds per hour. 3600 3600 3600 

Water vapor in the gas stream, proportion. 0.0723 0.0742 0.0783 

Area of stack in sq ft. 5.58 5.58 5.58 

Standard absolute temperature, 528 R. 528.00 528.00 528.00 

Standard absolute pressure, 29.92 in. Hg. 29.92 29.92 29.92 

Temperature of stack gas, + 460 (Rankine). 838.00 841.00 836.00 

Absolute stack gas pressure, barometric + static. 29.86 29.86 29.86 

Average stack gas velocity, ft/sec. 37.55 38.03 37.58 

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Page 9