Name: Scott Curry

Title: Plant Manager

Company: USG Interiors, Inc.

Sign Date:

Name: Randal J. Tysar

Title: Senior Environmental Engineer

Company: BT Environmental Consulting, Inc.

Sign Date:

Permitted Facility Representative / Date Testing Company Representative / Date

USG Interiors, Inc. Walworth, Wisconsin Cupola Residual Risk Emissions Test

Final Test Report 

for

/ /

Based on information and belief formed 

after reasonable inquiry, I certify that the 

statements and information in this test 

report are true, accurate, and complete.

I have reviewed all testing details and 

results in this test report and hereby 

certify that the test report is authentic 

and accurate.

Wednesday, February 09, 2011 Page 1 of 13
USG Interiors, Inc. Walworth, Wisconsin Cupola Residual Risk Emissions Test

Facility Information:

USG Interiors, Inc.

208 Adeline Street

Walworth WI 53184

Contact: Scott Curry

Phone: 262-275-2151

Fax:

Email:

Testing Company:

Pace Analytical Services, Inc.

1700 Elm Street, Suite 200

Minneapolis M 55414

Contact:Terry Borgerding

Phone: (612) 607-6374

Fax:

Email: terry.borgerding@pacelabs.com

Air Permit Number:

265006830-P01 FID 265006830

Permitted Source ID/Name:

WI 265006830-P01 FID 265006830

Permitted Maximum Process Rate:

NA

Max. Normal Operation Process Rate:

NA

Target Process Test Rate

Description of the source (including control equipment). Please see the attachments for source or

 process flow diagram:

USG produces mineral wool at its plant in Walworth. Mineral wool is produced by

melting and fiberizing raw materials. The major component is slag, which is a byproduct

from the steel industry. Stone and other additives are used to change the melt chemistry

to produce the best quality wool for production. The plant has a cupola for melting raw

materials. A cupola is a vertical cylindrical shaft furnace used to melt incoming minerals

and then direct the molten slag out of a discharge notch.

Main emission source involved in this process is the cupola, where the stone and slag

are heated and melted with coke. Pollution control equipment for the cupola includes a

baghouse and thermal oxidizer which includes a heat exchanger.

Industry/SCC/NAIS 327993

Sampling Location Information:

Test Parameter Information:

AFS #: 5512700004 FRS #: 110000417923

SCC / Description 30501701 Industrial Processes - Mineral Products - Mineral Wool - 

Cupola 

The following state and federal regulations that apply to the proposed testing:

Location

Round

Duct

Diam.

Distance from 

upstream dist.

Distance from

downstream dist.

Number of

Traverse Ports

Equiv. 

Diam

Min.Travers 

Points

Rect. Duct 

Length /Width

Afterburner 

Stack

41.5 324 452 2 0 0 0 12

Target

Parameter 

Test

Method

Number of

Test Runs

Test Run

Duration

Sample 

Location Points Comments

Afterburner Organic Condensible OTM - 27/28 3 180 0

Wednesday, February 09, 2011 Page 2 of 13
USG Interiors, Inc. Walworth, Wisconsin Cupola Residual Risk Emissions Test

The following describes any modifications and/or deviations to the applicable test 

methods. If alternative methods were requested, see the attachments for documentation 

of request AND approval, including dates.

Stack Particulate

Inorganic (Aqueous) 

Condensible Part.

Afterburner OTM - 27/28 3 180 0

Stack

Afterburner Total PM2.5 OTM - 27/28 3 180 0

Stack

Afterburner Filterable PM2.5 OTM - 27/28 3 180 0

Stack

Afterburner Chromium Method 29 3 180 0

Stack

Afterburner Arsenic Method 29 3 180 0

Stack

Afterburner Antimony Method 29 3 180 0

Stack

Afterburner Beryllium Method 29 3 180 0

Stack

Afterburner Lead Method 29 3 180 0

Stack

Afterburner Selenium Method 29 3 180 0

Stack

Afterburner Filterable Particulate Method 29 3 180 0

Stack

Afterburner Nickel Method 29 3 180 0

Stack

Afterburner Manganese Method 29 3 180 0

Stack

Afterburner Cobalt Method 29 3 180 0

Stack

Afterburner Cadmium Method 29 3 180 0

Stack

Afterburner Chromium Method 0061 3 180 0

Stack

Wednesday, February 09, 2011 Page 3 of 13
USG Interiors, Inc. Walworth, Wisconsin Cupola Residual Risk Emissions Test

Sampling / Stack Data Results Summary

Location Afterburner Stack - Method 0061

Average

Run Number 1A 2 3 

Test Date 9/23/2010 9/23/2010 9/23/2010 

Run Start Time 9:23:00 AM 11:46:00 

AM

1:44:00 PM 

Run Finish Time 10:48:00 AM 12:51:00 

PM

2:44:00 PM 

Net Run Time, minutes 60 65 65 

Dry Gas Meter Volume Sampled, dscf 35.470 36.309 34.833 35.537

Moisture Content of Stack Gas, % 5.03 4.92 5.02 4.990

Moisture Saturation at Stack Gas Temperature, % 100.00 100.00 100.00 100.000

Carbon Dioxide, % 6.12 6.21 5.66 5.997

Oxygen, % 13.73 13.62 14.18 13.843

Average Stack Gas Temperature, °F 269.33 291.58 300.25 287.053

Dry Volumetric Flow Rate, dry scfm 13,515.0 13,830.9 13,332.4 13,559.433

Actual Wet Volumetric Flue Gas Flow Rate, acfm 20,379.1 21,466.8 20,953.9 20,933.267

Percent Isokinetic of Sampling Rate, % 100.3 92.6 92.2 95.033

F-Factor, dscfm/MMBtu @ %O2 0 0 0 0.000

Fw 0 0 0 0.000

Fc 0 0 0 0.000

Wednesday, February 09, 2011 Page 4 of 13
USG Interiors, Inc. Walworth, Wisconsin Cupola Residual Risk Emissions Test

Location Afterburner Stack - Method 29

Average

Run Number 1 2 3 

Test Date 9/22/2010 9/22/2010 9/22/2010 

Run Start Time 7:35:00 AM 12:24:00 

PM

4:32:00 PM 

Run Finish Time 10:53:00 AM 3:43:00 

PM

8:00:00 PM 

Net Run Time, minutes 180 180 180 

Dry Gas Meter Volume Sampled, dscf 145.585 148.044 151.353 148.327

Moisture Content of Stack Gas, % 4.63 4.17 4.69 4.497

Moisture Saturation at Stack Gas Temperature, % 100.00 100.00 100.00 100.000

Carbon Dioxide, % 5.71 5.8 6.44 5.983

Oxygen, % 14.45 14.3 13.68 14.143

Average Stack Gas Temperature, °F 282.00 284.79 284.04 283.610

Dry Volumetric Flow Rate, dry scfm 14,218.2 14,477.5 14,557.1 14,417.600

Actual Wet Volumetric Flue Gas Flow Rate, acfm 21,675.3 22,047.2 22,267.0 21,996.500

Percent Isokinetic of Sampling Rate, % 100.0 99.9 101.5 100.467

F-Factor, dscfm/MMBtu @ %O2 0 0 0 0.000

Fw 0 0 0 0.000

Fc 0 0 0 0.000

Wednesday, February 09, 2011 Page 5 of 13
USG Interiors, Inc. Walworth, Wisconsin Cupola Residual Risk Emissions Test

Location Afterburner Stack - OTM - 27/28

Average

Run Number 1 2 3 

Test Date 9/22/2010 9/22/2010 9/22/2010 

Run Start Time 7:35:00 AM 12:24:00 

PM

4:32:00 PM 

Run Finish Time 11:08:00 AM 4:00:00 

PM

8:12:00 PM 

Net Run Time, minutes 206.8 204.1 202.9 

Dry Gas Meter Volume Sampled, dscf 78.491 76.178 78.504 77.724

Moisture Content of Stack Gas, % 3.81 3.57 4.41 3.930

Moisture Saturation at Stack Gas Temperature, % 100.00 100.00 100.00 100.000

Carbon Dioxide, % 5.71 5.8 6.44 5.983

Oxygen, % 14.45 14.3 13.68 14.143

Average Stack Gas Temperature, °F 281.86 285.14 284.19 283.730

Dry Volumetric Flow Rate, dry scfm 14,824.2 14,821.8 14,630.2 14,758.733

Actual Wet Volumetric Flue Gas Flow Rate, acfm 22,402.3 22,441.8 22,317.8 22,387.300

Percent Isokinetic of Sampling Rate, % 89.5 88.0 92.4 89.967

F-Factor, dscfm/MMBtu @ %O2 0 0 0 0.000

Fw 0 0 0 0.000

Fc 0 0 0 0.000

Wednesday, February 09, 2011 Page 6 of 13
USG Interiors, Inc. Walworth, Wisconsin Cupola Residual Risk Emissions Test

Emissions Summary

Location: Afterburner Stack - Method 0061

Compound: Chromium

Average

RunNumber 1A 2 3 

Mass_mg 0.00014 0.00016 0.00016 0.000

Elb/hr 7.06E-06 8.06E-06 8.10E-06 0.000

mg/dscm 1.39E-04 1.56E-04 1.62E-04 0.000

Location: Afterburner Stack - Method 29

Compound: Antimony

Average

RunNumber 1 2 3 

Mass_mg 0.00428 0.00031 0.000272 0.002

Elb/hr 5.53E-05 4.01E-06 3.46E-06 0.000

mg/dscm 1.04E-03 7.40E-05 6.35E-05 0.000

Compound: Arsenic

Average

RunNumber 1 2 3 

Mass_mg 0.06352 0.05417 0.06026 0.059

Elb/hr 8.21E-04 7.01E-04 7.67E-04 0.001

mg/dscm 1.54E-02 1.29E-02 1.41E-02 0.014

Compound: Beryllium

Average

RunNumber 1 2 3 

Mass_mg 0.00005 0.00005 0.00005 0.000

Elb/hr 6.46E-07 6.47E-07 6.36E-07 0.000

mg/dscm 1.21E-05 1.19E-05 1.17E-05 0.000

Compound: Cadmium

Average

RunNumber 1 2 3 

Mass_mg 0.0012 0.00173 0.00116 0.001

Elb/hr 1.55E-05 2.24E-05 1.48E-05 0.000

mg/dscm 2.91E-04 4.13E-04 2.71E-04 0.000

Compound: Chromium

Average

RunNumber 1 2 3 

Mass_mg 0.002822 0.002072 0.001212 0.002

Elb/hr 3.65E-05 2.68E-05 1.54E-05 0.000

mg/dscm 6.85E-04 4.94E-04 2.83E-04 0.000

Compound: Cobalt

Average

RunNumber 1 2 3 

Mass_mg 0.001074 0.000207 0.000519 0.001

Elb/hr 1.39E-05 2.68E-06 6.60E-06 0.000

mg/dscm 2.61E-04 4.94E-05 1.21E-04 0.000

Wednesday, February 09, 2011 Page 7 of 13
USG Interiors, Inc. Walworth, Wisconsin Cupola Residual Risk Emissions Test

Compound: Filterable Particulate

Average

RunNumber 1 2 3 

Mass_mg 11.3 3.1 5.1 6.500

Elb/hr 1.46E-01 4.01E-02 6.49E-02 0.084

mg/dscm 2.74E+00 7.40E-01 1.19E+00 1.557

Compound: Lead

Average

RunNumber 1 2 3 

Mass_mg 0.00398 0.00318 0.00127 0.003

Elb/hr 5.14E-05 4.11E-05 1.62E-05 0.000

mg/dscm 9.66E-04 7.59E-04 2.96E-04 0.001

Compound: Manganese

Average

RunNumber 1 2 3 

Mass_mg 0.00211 0.00663 0.00089 0.003

Elb/hr 2.73E-05 8.58E-05 1.13E-05 0.000

mg/dscm 5.12E-04 1.58E-03 2.08E-04 0.001

Compound: Nickel

Average

RunNumber 1 2 3 

Mass_mg 0.0002 0.0002 0.0002 0.000

Elb/hr 2.58E-06 2.59E-06 2.54E-06 0.000

mg/dscm 4.85E-05 4.77E-05 4.67E-05 0.000

Compound: Selenium

Average

RunNumber 1 2 3 

Mass_mg 1.277568 1.152968 1.231068 1.221

Elb/hr 1.65E-02 1.49E-02 1.57E-02 0.016

mg/dscm 3.10E-01 2.75E-01 2.87E-01 0.291

Location: Afterburner Stack - OTM - 27/28

Compound: Filterable PM2.5

Average

RunNumber 1 2 3 

Mass_mg 6.49 7.61 8.03 7.377

Elb/hr 1.62E-01 1.96E-01 1.98E-01 0.185

mg/dscm 2.92E+00 3.53E+00 3.61E+00 3.353

Compound: Inorganic (Aqueous) Condensible Pa

Average

RunNumber 1 2 3 

Mass_mg 2.22 17.4 23.1 14.240

Elb/hr 5.55E-02 4.48E-01 5.69E-01 0.358

mg/dscm 9.99E-01 8.07E+00 1.04E+01 6.490

Compound: Organic Condensible Particulate

Average

RunNumber 1 2 3 

Wednesday, February 09, 2011 Page 8 of 13
USG Interiors, Inc. Walworth, Wisconsin Cupola Residual Risk Emissions Test

Mass_mg 24.1 23.7 11.6 19.800

Elb/hr 6.02E-01 6.10E-01 2.86E-01 0.499

mg/dscm 1.08E+01 1.10E+01 5.22E+00 9.007

Compound: Total PM2.5

Average

RunNumber 1 2 3 

Mass_mg 32.81 48.71 42.73 41.417

Elb/hr 8.20E-01 1.25E+00 1.05E+00 1.040

mg/dscm 1.48E+01 2.26E+01 1.92E+01 18.867

Wednesday, February 09, 2011 Page 9 of 13
USG Interiors, Inc. Walworth, Wisconsin Cupola Residual Risk Emissions Test

Process Run Data

APCD Run Data

Process Lab Run Data

Run Name Value UOM Comments

Target

Value

1 Material Produced 0 Tons/hr M5/29 R1 0

2 Material Produced 0 Tons/hr M5/29 R2 0

3 Material Produced 0 Tons/hr M5/29 R3 0

4 Material Produced 0 Tons/hr OTM27/28 R1 0

5 Material Produced 0 Tons/hr OTM27/28 R2 0

6 Material Produced 0 Tons/hr OTM27/28 R3 0

7 Material Produced 0 Tons/hr M0061 R1 0

8 Material Produced 0 Tons/hr M0061 R2 0

9 Material Produced 0 Tons/hr M0061 R3 0

Wednesday, February 09, 2011 Page 10 of 13
USG Interiors, Inc. Walworth, Wisconsin Cupola Residual Risk Emissions Test

Sampling / Stack Data Results Detail

Location Afterburner Stack - Method 0061

Average

Run Number 1A 2 3 

Test Date 9/23/2010 9/23/2010 9/23/2010 

Run Start Time 9:23:00 AM 11:46:00 AM 1:44:00 PM 

Run Finish Time 10:48:00 AM 12:51:00 PM 2:44:00 PM 

Net Traversing Points 12 12 12 

Net Run Time, minutes 60 65 65 

Nozzle Diameter, inches 0.274 0.274 0.274 0.274

Pitot Tube Coefficient 0.84 0.84 0.84 0.840

Dry Gas Meter Calibration Factor 0.9948 0.9948 0.9948 0.995

Barometric Pressure, inches of Mercury 28.88 28.88 28.88 28.880

Average Orifice Meter Differential, inches H2O 1.32 1.39 1.27 1.327

Dry Gas Meter Volume Sampled, cubic feet 37.710 38.720 36.910 37.780

Average Dry Gas Meter Temperature, °F 80.83 82.58 78.96 80.790

Dry Gas Meter Volume Sampled, dscf 35.470 36.309 34.833 35.537

Total Moisture Liquid collected, g 40 40 39 39.667

Volume of Water Vapor, standard cubic feet 1.88 1.88 1.84 1.867

Moisture Content of Stack Gas, % 5.03 4.92 5.02 4.990

Moisture Saturation at Stack Gas Temperature, % 100.00 100.00 100.00 100.000

Dry Mole Fraction 0.9497 0.9508 0.9498 0.950

Carbon Dioxide, % 6.12 6.21 5.66 5.997

Oxygen, % 13.73 13.62 14.18 13.843

Carbon Monoxide & Nitrogen, % 80.15 80.17 80.16 80.160

Fuel Factor 1.17 1.17 1.19 

Dry Molecular Weight, lb/lb-Mole 29.53 29.54 29.47 29.513

Wet Molecular weight, lb/lb-Mole 28.95 28.97 28.89 28.937

Flue Gas Static Pressure, inches of H2O -0.27 -0.27 -0.27 -0.270

Absolute Flue Gas Pressure, inches of Mercury 28.86 28.86 28.86 28.860

Average Stack Gas Temperature, °F 269.33 291.58 300.25 287.053

Average Velocity Head, inches of H2O 0.2904044838

48226

0.312984703

17556

0.293933754

44438

0.299

Average Stack Gas Velocity, feet/second 36.16 38.09 37.18 37.143

Stack Cross-Sectional Area, square feet 9.393 9.393 9.393 9.393

Dry Volumetric Flow Rate, dry scfm 13,515.0 13,830.9 13,332.4 13,559.433

Actual Wet Volumetric Flue Gas Flow Rate, acfm 20,379.1 21,466.8 20,953.9 20,933.267

Percent Isokinetic of Sampling Rate, % 100.3 92.6 92.2 95.033

Percent Excess Air, % 184.8 180.5 203.1 189.467

F-Factor, dscfm/MMBtu @ %O2 0 0 0 0.000

Round Duct Diameter, inches 41.5 41.5 41.5 

Rectangular Duct Width, inches 0 0 0 

Rectangular Duct Length, inches 0 0 0 

Fw 0 0 0 0.000

Fc 0 0 0 0.000

Wednesday, February 09, 2011 Page 11 of 13
USG Interiors, Inc. Walworth, Wisconsin Cupola Residual Risk Emissions Test

Location Afterburner Stack - Method 29

Average

Run Number 1 2 3 

Test Date 9/22/2010 9/22/2010 9/22/2010 

Run Start Time 7:35:00 AM 12:24:00 PM 4:32:00 PM 

Run Finish Time 10:53:00 AM 3:43:00 PM 8:00:00 PM 

Net Traversing Points 12 12 12 

Net Run Time, minutes 180 180 180 

Nozzle Diameter, inches 0.313 0.313 0.313 0.313

Pitot Tube Coefficient 0.84 0.84 0.84 0.840

Dry Gas Meter Calibration Factor 0.9948 0.9948 0.9948 0.995

Barometric Pressure, inches of Mercury 28.94 28.94 28.94 28.940

Average Orifice Meter Differential, inches H2O 2.46 2.63 2.66 2.583

Dry Gas Meter Volume Sampled, cubic feet 154.010 157.890 160.200 157.367

Average Dry Gas Meter Temperature, °F 80.81 85.46 81.38 82.550

Dry Gas Meter Volume Sampled, dscf 145.585 148.044 151.353 148.327

Total Moisture Liquid collected, g 150 137 158 148.333

Volume of Water Vapor, standard cubic feet 7.06 6.45 7.44 6.983

Moisture Content of Stack Gas, % 4.63 4.17 4.69 4.497

Moisture Saturation at Stack Gas Temperature, % 100.00 100.00 100.00 100.000

Dry Mole Fraction 0.9537 0.9583 0.9531 0.955

Carbon Dioxide, % 5.71 5.8 6.44 5.983

Oxygen, % 14.45 14.3 13.68 14.143

Carbon Monoxide & Nitrogen, % 79.84 79.9 79.88 79.873

Fuel Factor 1.13 1.14 1.12 

Dry Molecular Weight, lb/lb-Mole 29.49 29.50 29.58 29.523

Wet Molecular weight, lb/lb-Mole 28.96 29.02 29.04 29.007

Flue Gas Static Pressure, inches of H2O -0.27 -0.27 -0.27 -0.270

Absolute Flue Gas Pressure, inches of Mercury 28.92 28.92 28.92 28.920

Average Stack Gas Temperature, °F 282.00 284.79 284.04 283.610

Average Velocity Head, inches of H2O 0.3237778070

34933

0.334363892

932055

0.341677779

423139

0.333

Average Stack Gas Velocity, feet/second 38.46 39.12 39.51 39.030

Stack Cross-Sectional Area, square feet 9.393 9.393 9.393 9.393

Dry Volumetric Flow Rate, dry scfm 14,218.2 14,477.5 14,557.1 14,417.600

Actual Wet Volumetric Flue Gas Flow Rate, acfm 21,675.3 22,047.2 22,267.0 21,996.500

Percent Isokinetic of Sampling Rate, % 100.0 99.9 101.5 100.467

Percent Excess Air, % 218.0 210.5 184.7 204.400

F-Factor, dscfm/MMBtu @ %O2 0 0 0 0.000

Round Duct Diameter, inches 41.5 41.5 41.5 

Rectangular Duct Width, inches 0 0 0 

Rectangular Duct Length, inches 0 0 0 

Fw 0 0 0 0.000

Fc 0 0 0 0.000

Wednesday, February 09, 2011 Page 12 of 13
USG Interiors, Inc. Walworth, Wisconsin Cupola Residual Risk Emissions Test

Location Afterburner Stack - OTM - 27/28

Average

Run Number 1 2 3 

Test Date 9/22/2010 9/22/2010 9/22/2010 

Run Start Time 7:35:00 AM 12:24:00 PM 4:32:00 PM 

Run Finish Time 11:08:00 AM 4:00:00 PM 8:12:00 PM 

Net Traversing Points 12 12 12 

Net Run Time, minutes 206.8 204.1 202.9 

Nozzle Diameter, inches 0.222 0.222 0.222 0.222

Pitot Tube Coefficient 0.84 0.84 0.84 0.840

Dry Gas Meter Calibration Factor 0.9955 0.9955 0.9955 0.996

Barometric Pressure, inches of Mercury 28.94 28.94 28.94 28.940

Average Orifice Meter Differential, inches H2O 0.46 0.47 0.47 0.467

Dry Gas Meter Volume Sampled, cubic feet 83.310 81.510 83.520 82.780

Average Dry Gas Meter Temperature, °F 80.25 84.64 81.54 82.143

Dry Gas Meter Volume Sampled, dscf 78.491 76.178 78.504 77.724

Total Moisture Liquid collected, g 66 60 77 67.667

Volume of Water Vapor, standard cubic feet 3.11 2.82 3.62 3.183

Moisture Content of Stack Gas, % 3.81 3.57 4.41 3.930

Moisture Saturation at Stack Gas Temperature, % 100.00 100.00 100.00 100.000

Dry Mole Fraction 0.9619 0.9643 0.9559 0.961

Carbon Dioxide, % 5.71 5.8 6.44 5.983

Oxygen, % 14.45 14.3 13.68 14.143

Carbon Monoxide & Nitrogen, % 79.84 79.9 79.88 79.873

Fuel Factor 1.13 1.14 1.12 

Dry Molecular Weight, lb/lb-Mole 29.49 29.50 29.58 29.523

Wet Molecular weight, lb/lb-Mole 29.05 29.09 29.07 29.070

Flue Gas Static Pressure, inches of H2O -0.27 -0.27 -0.27 -0.270

Absolute Flue Gas Pressure, inches of Mercury 28.92 28.92 28.92 28.920

Average Stack Gas Temperature, °F 281.86 285.14 284.19 283.730

Average Velocity Head, inches of H2O 0.3470440073

93757

0.347198593

029155

0.343473204

734951

0.346

Average Stack Gas Velocity, feet/second 39.75 39.82 39.60 39.723

Stack Cross-Sectional Area, square feet 9.393 9.393 9.393 9.393

Dry Volumetric Flow Rate, dry scfm 14,824.2 14,821.8 14,630.2 14,758.733

Actual Wet Volumetric Flue Gas Flow Rate, acfm 22,402.3 22,441.8 22,317.8 22,387.300

Percent Isokinetic of Sampling Rate, % 89.5 88.0 92.4 89.967

Percent Excess Air, % 218.0 210.5 184.7 204.400

F-Factor, dscfm/MMBtu @ %O2 0 0 0 0.000

Round Duct Diameter, inches 41.5 41.5 41.5 

Rectangular Duct Width, inches 0 0 0 

Rectangular Duct Length, inches 0 0 0 

Fw 0 0 0 0.000

Fc 0 0 0 0.000

Wednesday, February 09, 2011 Page 13 of 13