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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: 11/16/00Bowerston 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

12-3456-9

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.netEXECUTIVE 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 1ME'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 2METHOD 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 3R•OD 26A SAMPLING

APPARATUS

Custom .P. O. Box 3750 24385 C__er•ter Road Alliance, Ohio 44601 Phone: 330-525-5119

Fax: 330-525-7908

E-mail: customatac•ger.net Page 4 1Location 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 5CALCULATIONS OutletRUN #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 17.64Tm 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. 13.6Y 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

0.0471RUN #3

Custom Stack,•y•i•,

LLC P. O. Box 3750 24385 Center Road Alliance, Ohio 44601 Phone: 330-525-5119

Fax: 330-525-?908

E-mail: custom,•tacl@oyager.net Page 63= 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 #30.07834.3551.22

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

CustomStackA•udy•, [,LC P. O. Box 3750 24385 Center Road Alliance, Ohio 44601 Phone: 330-325-5119

Fax: 330-525-7908

E-mail: cmtomstac•voyager.net Page 7Ms 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

Custom Smck dnalysia, LLC P. O. Box 3750 24385 CenterRoad

Alliance, Ohio 44601 Phone: 330-525-5119

Fax: 330-525-7908

E-maib custo•ger.net Page 8RUN #1 9. Lbs/Hr

0.28 2.205 E-6 Mn'scfhVm 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

scfhRUN #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 0.0154Vm stdMn

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 3600BwsATstdPstdTsPsMs

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

Custom Stack Analy•is, LLC P. O. Box 3750 24385 Center Road zllliance, Ohio 44601 Phone: 330-525-5119

Far: 330-5.25-7908

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