Kiln Scrubber Stack 

rESTING LOCATION 

Gell Brick 

Road 

Ridge, Virginia 

PREPARED FOR 

Ms. Martha West 

General Shale Brick 

3211 N. Roan Street 

Johnson City, Tennessee 3 760 

March 2005 

Chris LeMay 

Project Manager 

PREPARED BY 

E. Roberts Alley & Associates, Inc. 

1931 Central Parkway SW, Suite S 

Decatm-, AL 35601 

Phone: (256) 351-0121 

Fax: (256) 351-0151 

ERA&A Project No. 2004-0675A 
Appendix A 

Appefidix B 

Appendix C 

•p•efidix D 

Appendix E 

General Shale Brick 

770 Webster Road 

Blue Ridge, Virginia 

TABLE OFCONTENTS 

Introduction Page 

1.1 Facility & Source Description 

1.2 Control Device Description 

1.3 Test Team & Contact Information .................................... 

1.4 Protocol/Methodology Deviations 

..................................... 1-1 

Summary of Results .......................................... 

Testing Methodology 

3.1 Volmnetric Flow Rate 

........................... 

Oxygen / Carbon Dioxide 

........................................................................... -2 Particulate Matter 

............................................................................................. 3-2 Particulate < 10 microns: .................................................................................... 3-2 Hydrogen Fluoride (Inlet) ............................................................... 3-3 Hydrogen Fluoride (Outlet) 

........................................................... -3 Sulfur Dioxide (Inlet) ......................................................................................... 3-3 Sulfur Dioxide (Outlet) ........................................................................ -3 Visible Emission Evaluations ............................................................................... 3-4 

APPENDICES 

Summary of Calculations 

Field Data 

Laborato W Data 

Quality Control Data 

Process Operating Data 
General Shale Brick 

770 Webster Road 

Blue Ridge, Virginia 

TABLE OF CONTENTS continued 

LIST OF TABLES 

Table 2-1 Summary of Emission Testing Results 

Table 2-2 Summary of PM-10/SO2 Testing Results 

Table 2-3 Summm'y of PM/HF Testing Results 

Table 3-1 Source Testing Methodology 

Table A- 1 PM-10/SO2 VFR Calculations 

Table A-2 PM-10/SO2 Emission Calculations 

Table A-3 PM/HF VFR Calctflations 

Table A-4 PM/HF Emission Calculations 

Table A-5 HF/SO2 Inlet Rate Calculations 
Introduction 
General Shale Brick 

•;,,•,,,,,J,,,,•,,•. •,•,,,,, ,•,•, •,•,,,,•, ,•. .•ti.•, Compliance Emission Test Report 

Introduction 

BI•e Riagei Vifgini• 

1.0 Introduction 

E. Roberts Alley & Associates, Inc. (ERA&A) compliance emission testing 

was retained by General Shale Brick (General Shale) to conduct 

purpose of the testing was to demonstrate 

on the Kiln Scrubber Stack at its Blue Ridge, Virginia facility (facility #20447). The compliance with emission limits detailed in the facility's air permit. 

1.1 Facility and Source Description 

crushed 

General 

and 

Shale's 

sent 

Blue 

through 

Ridge Facility manufactures brick exterior building material. Shale and clay are mined, a screening process prior to brick forming. The brick is formed by extrusion. Once the brick is extruded, it is dried and fired in 

Facility has two Kilns (A & B) with 

a tunnel Kiln at approximately 2,000 degrees Fahrenheit. The Blue Ridge 

shipped to varions locations. 

a common exhaust. After being fired, the brick is cooled, packaged and 

1.2 Control System Description 

The Kiln emissions are controlled with a lime-injected, dry scrubber. The emission testing was performed scrubber exhaust stack located outside on the the kiln building on the east side. 

1.3 Test Team and Contact Information 

Cunningham, 

The emission 

Isokinetic 

testing was 

Train 

conducted 

Operator, 

by Mr. Ryan O'Dea, Team Leader/Mobile Lab Operator, Mr. Stacey and Mr. Dusten Dutton, Technician. Instrumental test data was recorded on site in ERA&A's mobile laboratory. Mr. GaD' Jones and Mr. Mike Whitehead of General Shale served as ERA&A's on-site contacts and coordinated the testing with facility operations. 

1.4 Protocol/Method Deviations 

Reference 

ERA&A's 

Method 

last protocol 

6C would 

(General 

be used 

Shale Roanoke Protocol Rev. 2), dated February 17, 2005, stated that EPA to determine the inlet sulfur dioxide mass rate while the outlet emission rate would be measured in accordance with EPA Method 6. Before the received approval to 

on site testing was initiated, General Shale use Kiln fuel (coal and natural gas) data to calculate the inlet sulfur dioxide Therefore, ERA&A measured the outlet emission mass rate. rate in accordance with EPA Method 6C. 

E RA&A 

did use an 

s protocol 

AP-42 emission 

did not reference 

factor 

inlet hydrogen fluoride sampling or emission estimation procedures. ERA&A 

removal efficiency. 

to calculate the inlet hydrogen fluoride rate to satisfy a facility permit required 

c:\\Projects\Ge neralS hale\2005_0077\EmissioffrestReport 

Page 1-1 
Results 
General Shale Brick 

Compliance Emission Test Report 

Summaly of Results 

2.0 Summary of Results 

ERA&A conducted a total of three (3) test runs for Particulate Matter and Hydrogen Fluoride and three (3) test on February 23, 2005 runs for Particulate < 10 microns and Sulfur Dioxide conducted on the Kiln Scrubber exhaust 

on February 24, 2005. All testing was stack. The arithmetic determine source compliance for each pollutant. 

average of these three (3) test runs was used to Tables 2-1 through 2-3 contain testing results. Any difference a summary of the compliance 

contained in Appendix A is 

between the summary results listed in the following tables and the detailed results due to rounding for presentation. 

TABLE 2-1 

•;UMMARY OF EMISSION TESTING RESULTS 

Emission Rate, Ibs/hr 3.3 2.6 3.3 3.0 Permitted Limit, [bs/hr 

Percent of Limit, % 19.6 

Sulfi•r Dioxide 

Emission Rate, lbs/hr 

Permitted Limit, Ibs/hr 

Percent of Limit, % 

Sulfur Dioxide Control 

Control Efficiency, % 

Permitted Limit, % 

Particulate Matter 

Emission Rate, lbs/hr 

Permitted Limit, lbs/hr 

Percent of Limit, % 

Hydrogen Fluoride 

Emission Rate, lbs/hr 

Hydrogen Flnoride Control 

Control Efficiency, % 

Permitted Limit, % 

15.4 15.9 

36 16 

5.5 4.9 

0.07 0.08 

97 97 

15.6 

17 

8.0 

0.07 

97 

16 

15.6 

36.72 

43 

23 

10 

25.2 

24 

0.07 

97 

o• 

c:\\Projects\GeneralShalek2005-0077\EmissionTeslRepo•l 

Page 2-1 
General Shale Brick 

Compliance Emission Test Report 

Summary of Results 

TABLE 2-2 

SUMMARY Ot• PM-I 0/SO2 TESTING J•ESULTS 

Date 

Start Trine 2/24/05 2/24/05 2/24/05 

Stop Time 8;07 9:49 11:22 

Run Time (PM9:12 10:51 12:24 10), rain 

Run Time (SO2), 62.39 56.31 61.55 rain 60 60 60 rrocess Oata 

Gas Used, x l03 SCF 

Coal Used, 7.81 7.45 8.24 lbs 1,424 1,470 1,454 Control Data 

Lime Feed Rate, lbs/hr 

Sulfur 92.6 92.6 92.6 Dioxide Inlet 

SO2 from Gas, x 10 -3 lbs/hr 

SO2 from 4.5 4.2 4.7 Coal, lbs/hr 

SO2 Total, 24.2 18.9 18.7 lbs/hr 24.2 18.9 18.7 Stack Conditions 

Temperature, °F 

Moisture, 283 281 281 % 

Velocity, 7.7 7.9 7.9 fps 

VFR, 24.6 24.7 24.5 x 104 dscfm 

Particulate 

2.3 2.3 2.3 < l0 microns 

Concentration, x 10 .2 grains/dscf 

Emission 1.7 1.3 1.7 Rate, lbs/hr 

Sulfur 

3.3 2.6 3 g Dioxide Outlet 

Concentration, ppmvd 

Emission 68.7 70.2 69.4 Rate, lbs/hr 15.4 15.9 15.6 Based on an AP-42 emission factor of 0.6 pounds per 

Based 

106 standard cubic feet and assuming 95% conversion on fuel samples and analyses for sulfur content and assuming 95% conversion 

60.08 

7.83 

1,449 

92.6 

4.5 

20.6 

20.6 

282 

7.8 

24.6 

2.3 

1.6 

69,4 

1516 

c:\\Projects\GeneralShale\2005_0077\EmissionTestRepo•l 

Page 2-2 
General Shale Brick 

•:,,,•,,,,,,,,.,,t,,/. •,•,,•,,.,. •,,,7/,J,,• x•.t.. Compliance Emission Test Report 

Summary of Results 

TABLE 2-3 

SUMMARY O• PM/HF TESTING •ESULTS 

Start Time 

Stop Time 

Run Time, rain 

Production Data 

Bricks fired per hour 

Brick weight (each), lbs 

Hydrogen Fluoride Inlet 

Emission Rate, lbs/hr" 

Stack Conditions 

Temperature, °F 

Moisture, % 

Velocity, fps 

VFR, x 104 dscfm 

Pa rticulate Matter 

Concentration, x 10 -• 

grains/dscf 

Emission Rate, Ibs/hr 

Hydrogen Fluoride Outlet 

15:07 

60 

17:10 

18:13 

60 

278 

8.6 

23.5 

2.2 

3.0 

5.5 

16:46 

60 

280 

8.0 

22.6 

2.1 

2.7 

4.9 

Emission Rate, lbs/hr 0.07 0.08 

Based on an AP-42 factor of 0.17 pounds Hydrogen Fluoride per ton of brick fired 

279 

8.5 

23.1 

2.1 

4.4 

8.0 

0.07 

8,229 

3.6 

2.52 

279 

8.4 

23.1 

2.1 

3.4 

6il 

• (Y7 

c:\•Projects\GeneraiShaleL2005_0077\EmissionTestReport 

Page 2-3 
Testing Methodology 
General Shale Brick 

L•,.•,,,,,,,,.,,•,Tz •:,,•,•,,.,.,,•, •,.•,•, •..•;,,/i.,,. Compliance Emission Test Report 

Testing Methodolo• 

Ge•6ral Shale B•ic• ..... • 

•dg• virginia 

3.0 Testing Methodology 

The emission testing program was conducted in accordance with the U.S. EPA Reference Methods summarized in Table 3-I. Method descriptions and quality assurance data are provided in the referenced appendices. 

TABLE 3-1 

SOURCE TESTING •/IETHODOLOG¥ 

Volumetric Flow Rate 

Oxygen/Carbon Dioxide 

Particulate Matter 

Particulate < 10 microns 

Hydrogen Fluoride (Inlet) 

Hydrogen Fluoride (Outlet) 

Sulfur Dioxide (Inlet) 

Sulfur Dioxide (Outlet) 

Visible Emissions 

1,2,3A,4 3.1 D 

3A 3.2 D Instrumental Analysis 5 3.3 D Isokinetic Sampling 201A 3.4 D Constant Rate Sampling AP-42 Factor 3.5 D Calculated 

26A 3.6 D Isokinetic Sampling AP-42 Factor 3.7 D Coal Analysis/Calculated 6C 3.8 D Instrumental 

9 3.9 D Certified Evaluator 

3.1 Volmnetric Flow Rate 

The 

1. The 

sampling 

stack gas 

location 

velocity 

and number of traverse points were selected in strict accordance with EPA Reference Method pressure was measured using an S-type pitot and an inclined manometer. The velocity of 

were 

the stack 

used 

gas 

to measure 

was determined 

the 

in strict accordance with EPA Reference Method 2. A total of twelve traverse points average stack gas velocity pressure. 

The oxygen and carbon monoxide concentrations 3A. See Section 3.2 for Method 3A 

were determined in strict accordance with EPA Reference Method testing methodology. The stack accordance with EPA Method 4. The 

gas moisture content Was determined in strict 

impingers contained 100 mL of 

moisture removal system consisted of four (4) impingers. The first two (2) water, the third impinger grams of silica gel. The impinger was empty, and the fourth contained approximately 200 

after each test run. 

contents were either measured gravimetrically and/or volumetrically before and 

c:\\Projects\GeneralShale\2005_OO77•EmissionTestReporl 

Page 3-1 
General Shale Brick 

Compliance Emission Test Report 

Test#tg Methodology 

3.2 Oxygen / Carbon Dioxide 

The concentrations of oxygen and carbon dioxide in the stack gas were determined in strict accordance with EPA Reference 

line(s), 

Method 3A. The stack gas was withdrawn through a stainless sample probe, heated Teflon sample and gas conditioning system to a CAI Model 200P O2/CO2 analyzer. The gas conditioning system was a non-contact condenser used to remove the stack gas moisture. Data was acquired online and reported in one-minute averages. 

An analyzer calibration and system bias check were performed before testing was initiated. A system bias/drift check was also conducted following the completion of each 60-minute test run. Additional analyzer calibrations were conducted as needed. EPA Protocol calibration gases were used to conduct analyzer calibrations, drift checks, and system bias checks. ERA&A also utilized 

dilution system 

a laboratory and field certified (EPA Method 205) gas to accurately split high range calibration gas to meet the requirements of EPA Reference Method 3A. Copies of all calibration gas certificates and Method 205 data can be found in Appendix D. 

3.3 Particulate Matter 

The particulate testing was conducted in strict accordance with EPA Reference Method 5. The sampling train consisted of a glass nozzle, glass-lined probe, pre-weighed Teflon filter, Three gas conditioning system, and dry gas meter. (3) 60-minute test runs were conducted on the scrubber stack. The gas stream was sampled isokinetically by adjusting the sample flow rate to correspond to the flow conditions at each sampling (traverse) point. After each test run, the sample train was leak checked at a vacuum pressure equal to or greater than the maximum pressure reached during the test run. 

The probe and nozzle were rinsed with acetone after each run to remove the adhering particulate matter. The front half of the filter holder was also rinsed with acetone, and this rinse was added to the probe/nozzle rinse. The weighed filter prewas carefully removed and placed in its sample container. All containers were sealed, labeled, and liquid levels marked for transport to the ERA&A laboratory in Decatur, Alabama. 

The mass of particulate matter collected in the probe and nozzle was determined by evaporating the acetone rinse in a pre-weighed glass beaker and then weighing the residue until a constant weight was obtained. The filter loading was determined by subtracting the final constant filter weight from the initial constant weight. The total particulate loading, which was used to calculate the concentration of particulate matter in the exhaust gas, was determined by adding these two weights. All weight measurements were made on the same balance (accurate to 0.1 rag). 

3.4 Particulate < 10 microns (PM-10) 

The PM-10 concentration in the stack gas was determined in strict accordance with EPA Reference Method 201A. The PM-10 in the source gas was withdrawn at a constant rate through a stainless steel nozzle, cyclone, and collected on an in-stack glass fiber filter. Three (3) 60-minute test runs were conducted on the scrubber stack. 

Following the completion of each test run, ERA&A recovered the filter in sample Container 1. The PM-10 portion of the cyclone was rinsed with acetone and collected in sample Container 2. The nozzle and greater than PM-10 side of the cyclone were rinsed with acetone and the rinse was discarded. ERA&A performed the filterable PM-10 analysis at its laboratory in Decatur, Alabama. 

c:\\Projects\GeneralShale\2005.0077\EmissionTestRepor• Page 3-2 
Alle e 

AssoCiates General Shale Brick 

Compliance Emission Test Report 

Testing Methodology 

3.5 Hydrogen Fluoride (Inlet) 

The inlet hydrogen fluoride rate was determined using an AP-42 factor of 0.17 pounds per ton of brick fired. General Shale provided production data which allowed ERA&A to calculate the tons of brick fired hydrogen per hour. The fluoride inlet rate was calculated based on the AP-42 factor and production data. 

3.6 Hydrogen Fluoride (Outlet) 

conjunction 

The hydrogen fluoride emission testing was conducted in strict accordance with EPA Reference Method 26A and in 

impinger, 

with the particulate emission testing. After determining the amount of condensed moisture in each the absorbing solution (0.1 N H2SO4) from the first and second impingers and the absorbing solution (0.1 N NaOH) from the third and fourth impingers were placed into separate 1000 mL glass sample containers. The back 

placed 

half of the filter holder and all glassware leading to the outlet of the second impinger was rinsed with DI water and in the H2SO4 absorbing solution sample container. All glassware, from the inlet of the third impinger to the outlet of the fourth impinger, 

container. 

was rinsed with DI water and placed in the NaOH absorbing solution sample All of the samples were sealed, labeled, and liquid levels marked for transport to PSC Analytical Services in Burlington, Ontario, Canada. 

3.7 Sulfur Dioxide (Inlet) 

The inlet sulfur dioxide rate is the combined sulfur dioxide rate from coal and gas used during each test run. The inlet SO2 rate from gas was calculated using an AP-42 factor of 0.6 pounds of SO2 per million standard cubic feet of 

during 

gas and assuming 95% conversion. To determine the SO2 rate from coal, General Shale procured coal samples each test run and submitted them to Standard Laboratories, Freeburg, Illinois for sulfur analysis. ERA&A calculated the SO2 concentration on a dry basis assuming 95% conversion. The average coal SO2 and combined gas SO2 were to determine the average inlet SO2 rate. 

3.8 Sulfur Dioxide (Outlet) 

The sulfur dioxide outlet testing was conducted in strict accordance with EPA Reference Method 6C. Three (3) 60- minute test runs were performed on the scrubber exhaust gas. The stack gas was withdrawn through a stainless sample probe, heated Teflon sample line(s), and gas conditioning system to a Western Research Model 721M SO2 analyzer. The gas conditioning system was a non-contact condenser used to remove the stack gas moistm'e. Data was acquired online and reported in one-minute averages. 

An analyzer calibration and system bias check were performed before testing was initiated. A system bias/drift check was also conducted following the completion of each 60-minute test run. Additional analyzer calibrations were conducted as needed. EPA Protocol calibration gases were used to conduct analyzer calibrations, drift checks, and system bias checks. ERA&A also utilized 

dilution 

a laboratory and field certified (EPA Method 205) gas system to accurately split high range calibration gas to meet the requirements of EPA Reference Method 3A. Copies of all calibration gas certificates and Method 205 data can be found in Appendix D. 

c:\\Projects\GeneralShale\2005-0077\EmissionTestReport Page 3-3 
Asse a es 

General Shale Brick 

Compliance Emission Test Report 

Testing l•fethodology 

3.9 Visible Emission Evaluations 

opacity 

The visible emission evaluations (VEEs) were conducted in strict accordance with EPA Reference Method 9. The 

second intervals 

was evaluated for one-hour periods during each particulate test run. Opacity readings were read at fifteen- and recorded 

distance 

on a field data sheet. The field data also consisted of the stack height, evaluators 

background, 

and 

plume 

direction from the source, wind direction, wind speed, ambient temperature, sky conditions, color of color, and the angle of the sun in relation to the observer and the emission source. A Certified visible evaluator conducted all of the VEEs. Copies of the visible emission evaluators' certification in Appendix can be found D. 

c:\\Proj ects\GeneralS hale\2005.0077\EmissionTestRepor• 

Page 3-4 
Appendix A 
Biu6 

770 Web•i•{ R0ad • 

•dgel V•ginia 

General Shale Brick 

Compliance Emission Test Report 

Summwy of Calculations 

SAMPLE CALCULATIONS 

Meter Pressure (Pro), in. Hg 

Run 1, PM/HF, 2/23/05 

AH Pm Pb + 

13.6 

Pm 30.21 in. Hg + 

where, Pb barometric pressure, in. Hg 

AH Pressure differential of orifice in. H20 1.383 in. H20 30.31 in. Hg 13. 6 in. H20/in. Hg 

Absolnte Stack Gas Pressure (Ps), in. Hg 

Ps Pb + Pg 

13.6 

where, 

Ps 0.10 in.HeO 30. 21 in. Hg + 

13.6 in. H20/in. Hg 

Pb barometric pressure, in. Hg 

Pg Static Pressure, in. H20 

30.22 in. Hg 

Standard Meter Volume (Vmstd), dscf 

Vmstd 

17.647 × Y × Vm ×Pm 

Tm 

where, Y meter correction factor 

Vm meter volume, cf 

Pm= meter pressure, in. Hg 

Tm meter temperature, °R 

17. 647 °R/in. Hg x 1.008 x 37.087 cf x 30. 31 in. Hg 

530. 3 °R 37. 706 dscf 

c:\•Projects\GeneralShale\2005.0077\EmissionTestRepm• 

Page A-1 
Standard Wet Volume (Vwstd), scf 

Vwstd O. 04 70 7 x Vlc 

where, 

Vwstd=O.O4707 fi3/mLx75.6 mL 3.558 scf 

General Shale Brick 

Compliance Emission Test Report 

Summary of Calculations 

Vlc volume of H20 collected, ml 

Moisture Fraction (Bws) 

Bws Vwstd 3.558 scf 

(Vwstd + Vmstd) 3.558 scf + 37. 706 dscf 

O. 086 

where, Vwstd standard wet volume, scf 

Vmstd standard meter volume, dscf 

Moisture Content (MC), % 

MC BwsxlO0 0,086x100 8.6% 

where, 

Molecular Weight (DRY) (Md), Ib/lb-mole 

Bws moisture fraction, dimensionless 

Md (0. 44 x % CO:) + (0.32 x % 0•) + (0.28 (100- % CO:- % 0•)) 

Md (0.44 x 3.8) + (0.32 x 16.7) + (0.28 (100 3.8 16. 7)) 29.28 lb/lb mole 

CO2 carbon dioxide concentration, %d 

02 oxygen concentration, %d 

Molecular Weight (WET) (Ms), lb/Ib-mole 

where, 

Ms Md (1 Bws) + 18 (Bws) 

where, Md molecular weight (DRY), lb/lb-mole 

Bws moisture fraction, dimensionless 

Ms 29.28 Ib/lb-mole (1-0.086) +18(0.086) 28.30 lb/lb-mole 

Average Velocity (Vs), ft/sec 

Vs=85.49 xCpx•P avg. x] Ts 

Psx Ms 

c:\•'roj ects\GeneralShaleL2005-0077\EmissionTestRepm• Page A-2 
scc (°R)On.H20) 

Vs 23.5 fi/sec 

where, 

General Shale Brick 

Compliance Emission Test Report 

Summary of Calcalations 

Cp pitot tube coefficient 

Delta P velocity head of stack gas, in. H20 

Ts absolute stack temperature, °R 

Ps absolute stack gas pressure, in. Hg 

Ms molecular weight of stack gas, lb/lb-mole 

×0.84x0.352 in. H20x I 737.6 °R 

30.22 in. Hgx28.30 lb/lb-mole 

Average Stack Gas Flow at Stack Conditions (Qa), acfm 

Qa 60 x Vs x As 

where, 

Qa 

Vs stack gas velocity, ft/sec 

As cross-sectional area of stack, ft z 

60 sec/min x 23.5 fi/sec x 23.22 fi: 3:3E +04 acfm 

Average Stack Gas Flow at Standard Conditions (Qs), dscfm 

Qs =17.647 x Qax (1- Bws) x-- 

Ts 

where, Qa average stack gas flow at stack conditions, ft3/min 

Bws moisture fraction (dimensionless) 

Ps absolute stack gas pressure, in. Hg 

Ts absolute stack temperature, °R 

R Qs=17.647--x3.3E+04 acf x(l_O.086) x 

in. Hg rain 

30.22 in. Hg 

737. 6 °R 

2:2 E • 04 dscfm 

Particulate Coucentration (cs), grains/dscf 

C S 

M,, x0.0154 

Vmstd 

where, 

72.3mgx 0.0154 grains/mg 

37.706 dscf 

Mn particulate mass from filter and fi'ont half rinse, mg 

Vmstd standard meter volume, dscf 

3.0 E 02 grains / dscf 

c:\\Projects\GeneralShale'O.005-0077\EmissionTestReport Page A-3 
Particulate Emission Rate (PMR), lbs/hr 

c.,. xQs'x 60 

PMR 

7000 

where, 

General Shale Brick 

Compliance Emission Test Report 

Summary of Calculations 

c• particulate concentration, grains/dscf 

Qs stack gas flow at std. cond., dscfm 

PMR 3.0 E 02 grains/dscf× 2.2E + 04 dscf/min×6Omin/hr 

7000 grains / lb 5.47 lbs / hr 

HF Emission Rate (ER•v), lbs/hr 

MHr xQ,,. x60 

v,,,.•,ct 4.54E + 05 

where, 

0.9rag x 2.2 E + 04 dscfm x 60min/hr 

37.706dscfx 4.54E + 05 mg 

lb 

MHF HF mass, mg 

Qs stack gas flow at std. cond., dscfm 

Vmstd standard meter volume, dscf 

0.07 lbs / hr 

SO2 Emission Rate (ERso2), Ibs/hr 

ERso,. Cso, x MWso" x Qs x 60 x 28. 32 

24. 04 x 1. OE + 06 x 454 

where, Cso2 SO2 concentration, ppmvd 

MWso2 SO 2 molecular weight (64.1 g/g-mole) 

Qs outlet volumetric flow rate, dscfm 

ERso 2 

68. 7 uL/L x 64.1 g/g mole x 2.3 E + 04 dscfm x 60 min/hr x 28.32 L/cf 

24. 04 L/g mole x 1. OE + 06 uL/L x 454 g/lb 15.43 lbs / hr 

HF Inlet Rate (IRrw), Ibs/hr 

]R HF 2000 

where, AP AP-42 factor, lbs/ton of brick fired 

Pb brick Production, brick fired/hour 

Wb brick weight, Ibs 

c:\\Projects\GeneralShale\2005-0077\EmissionTestReport Page A-4 
General Shale Brick 

Compliance Emission Test Report 

Summary of Calculations 

O. 17lbs / ton brick × 8, 229 bricks/hr × 3.6 lbs / brick 

2.521bs / hr 2000 lbs / ton 

HF Removal Efficiency (RE,w), % 

IRHF ERH• REm: × 1 O0 

[RHF 

2. 5 21bs/hour O. 07 lbs.hour 

2. 521bs/hour × 100 97.2% 

SO2 Inlet Rate (IRso2), lbs/hr 

__Gas, (IRGso__•2) 

IRGso,. AP × GR x C where, AP AP-42 factor, lbs/1.0E+06 scf 

GR gas used x 1.0E+03 scf 

C conversion, assuming 95% 

IRGso2 0.6 Ibs/1.OE + 06 scf x 7.81E + 03 scf × 0.95 4.5E 03 lbs / hr 

Coal (IRCso,,•z) 

IRCso: CR × (1 MC 0 x SC x C x 2 

where, CR coal used, lbs/hr 

MCc coal moisture fraction 

SC coal sulfur content 

C conversion, assuming 95% 

IRCso_, 1,4241bs/hour x (1 0.0161) x 0.0091 x 0.95 x 

64.1 g / gmole 

32.1 g / gmole 

IRCso., 24.2 lbs/hour 

Tota____] 

IRso•, IRGso: + IRCso• 24.2 lbs / hr 

c:\\Prqiects\Genera S hale\2005-0077\EmissionTestReport Page A-5 
TABLE A-1 

PM- 10/S Oz VFR CALCULATIONS 

General Shale Brick 

Compliance Emission Test Report 

Summary of Calculations 

Run Number 2 3 Average Date 02/24/05 02/24/05 02/24/05 

Start Time 8:07 AM 9:49 AM 11:22 AM 

Stop Time 9:12 AM 10:51 AM 12:24 PM 

Run Time, rain 62.39 56.31 61.55 60.08 

Point 0.13 0.15 0.14 0.14 Point 2 0.14 0.14 0.13 0.14 Point 3 0.13 0.14 0.13 0.13 Point 4 0.13 0.13 0.14 0.13 Point 5 0.13 0.14 0.13 0.13 Point 6 0.13 0.14 0.13 0.13 Point 7 0.15 0.14 0.14 0.14 Point 8 0.14 0.14 0.14 0.14 Point 9 0.13 0.14 0.13 0.13 Point 10 0.13 0.13 0.13 0.13 Point 11 0.13 0.13 0.13 0.13 Point 12 0.14 0.12 0.14 0.13 

Square Root of Delta P, (in. H20) 

Pitot Tube Coefficient (Cp) 

Barometric Pressure (Pb), in. Hg 

Static Pressure (Pg), in. H20 

Stack Pressure (Ps), in. Hg 

Stack Diameter, in. 

Stack Cross-sectional Area, ft 

Temperature (Ts), 

Moisture Content (MC), % 

CO2 Concentration (CO2), % 

02 Concentration (O2), % 

Molecular Weight (Md), lb/lb-mole (dry) 

Molecular Weight (Ms), lb/lb-mole (wet) 

ft/sec 

0.366 0.370 0.366 0.367 

0.84 0.84 0.84 0.84 

30.05 30.05 30.05 30.05 

0.10 0.12 0.12 0.11 

30.06 30.06 30.06 30.06 

65.3 65.3 65.3 65.3 

23.22 23.22 23.22 23.22 

283.3 281.2 280.5 281.7 

7.7 7.9 7.9 7.8 

3.6 3.7 3.8 3.7 

16.3 16.3 16.3 16.3 

29.23 29.24 29.26 29.24 

28.37 28.36 28.37 28.36 

24.6 24.7 24.5 24.6 

Volumetric Flow Rate 

At Stack Conditions (Qa), ACFM 

At Standard Conditions (Qs), DSCFM 

34,210 34,476 34,148 34,278 

22,538 22,735 22,518 22,597 

c:\\Projects\GeneralShale\2005-0077\EmissionTestReport Page A-6 
General Shale Brick 

Compliance Emission Test Report 

Summary of Calculations 

TABLE A-2 

PM-10/SO2 EMISSION CALCULATIONS 

Run Number 

Date 

Start Time 

Time 

Run Time (PM-10), rain 

Run Time (SO2), rain 

Barometric Pressure, in. Hg 

Meter Correction Factor 

Orifice Calibration Value 

Meter Volume, ft 

Meter Temperature, °F 

Meter Orifice Pressure, in. H20 

Volume H20 Collected, mL 

Nozzle Diameter, in 

Area of Nozzle, ft 

Filterable PM-10 Mass, mg 

Sulfur Dioxide Concentration, 

Standard Meter Volume, ft 

Standard Water Volume, ft 

Moisture Fraction (Measured) 

Meter Pressure, in Hg 

Volnme at Nozzle, ft 

Isokinetic Sampling Rate, % (+/- 20%) 

Orifice Calibration Checks, % (+/- 5%) 

Filterable PM-10 Concentration, gr/dscf 

Filterable PM-10 Emission Rate, Ibs/hr 

SO2 Emission Rate, lbs/hr 

2 3 Average 

02/24/05 02/24/05 02/24/05 

8:07 AM 9:49 AM 11:22 AM 

9:12 AM 10:51 AM 12:24 PM 

(0pMio) 62.39 56.31 61.55 60.08 

(0so2) 60 60 60 60 

(Pb) 30.05 30.05 30.05 30.05 

(Y) 1.008 1.008 1.008 1.008 

(Delta H@) 1.968 1.968 1.968 1.968 

(Vm) 24.126 22.471 24.358 23.652 

(Tm) 66.7 69.0 68.8 68. 

(Delta H) 0.575 0.576 0.575 0.575 

(Vlc) 43.3 41.2 45.2 43.2 

(Dn) 0.264 0.264 0.264 0.264 

(An) 0.00038 0.00038 0.00038 0.00038 

(Mn) 26.9 19.7 27.0 24.5 

68.7 70.2 69.4 69.4 

(Vmstd) 24.521 22.740 24.657 23.973 

(Vwstd) 2.038 1.939 2.128 2.035 

(BWS) 0.077 0.079 0.079 0.078 

(Pro) 30.09 30.09 30.09 30.09 

(Vn) 37.22 34.48 37.39 36.37 

(I) 106.5 108.5 108.7 107.9 

(Ycheck) -3.2% -0.3% -1.0% -1.5% 

(Cs) 0.0169 0.0133 0.0169 0.0157 

(PMR) 3.26 2.60 3.25 3.04 

(ERso2) 15.43 15.90 15.57 15:63 

c:\\Proj ects\GeneralS hale\2005-0077\EmissionTestRepol.t Page A-7 
TABLE A-3 

PNI/HF VFR CALCULATIONS 

General Shale Brick 

Compliance Emission Test Report 

Summary of Calculations 

Run Number 

Date 

Start Time 

Stop Time 

Run Time, rain 

2 3 Average 

02/23/05 02/23/05 02/23/05 

2:01 PM 3:40 PM 5:10 PM 

3:07 PM 4:46 PM 6:13 PM 

60 60 60 60 

Point 

Point 2 

Point 3 

Point 4 

Point 5 

Point 6 

Point 7 

Point 8 

Point 9 

Point 0 

Point 11 

Point 12 

0.13 0.12 0.12 0.12 

0.13 0.13 0.13 0.13 

0.12 0.12 0.13 0.12 

0.13 0.11 0.12 0.12 

0.12 0.10 0.11 0.11 

0.12 0.11 0.13 0.12 

0.12 0.12 0.12 0.12 

0.13 0. I1 0.13 0.12 

0.12 0.12 0.13 0.12 

0.12 0.12 0.12 0.12 

0.13 0.12 0.10 0.12 

0.12 0.10 0.10 0.11 

Square Root of Delta P, (in. H20) 

Pitot Tube Coefficient (Cp) 

Barometric Pressure (Pb), in. Hg 

Static Pressure (Pg), in. H20 

Stack Pressure (Ps), in. Hg 

Stack Diameter, in. 

Stack Cross-sectional Area, ft'x2 

Temperature (Ts), 

Moisture Content, % 

CO2 Concentration (CO2), % 

02 Concentration (02), % 

Molecular Weight (Md), lb/lb-mole (dry) 

Molecular Weight (Ms), lb/lb-mole (wet) 

ft/sec 

0.352 0.339 

0.84 0.84 

30.21 30.21 

0.10 0.10 

30.22 30.22 

65.3 65.3 

23.22 23.22 

"277.6 ,279.8 

8.6 8.0 

3.8 3.8 

"16.7 16.7 

29.28 29.28 

28.30 28.39 

23.5 22.6 

0.346 

0.84 

30.21 

0.11 

30.22 

65.3 

23.22 

279.4 

"8.5 

3.6 

17.0 

29.26 

28.30 

23.1 

0.346 

0.84 

30.21 

0.10 

30.22 

65.3 

23.22 

2789 

8:4 

3.7 

168 

29.27 

28.33 

23.1 

Volumetric Flow Rate 

At Stack Conditions (Qa), ACFM 

At Standard Conditions (Qs), DSCFM 

-32,735 31,484 32,196 32;138 

21,625 20,915 21,243 21,261 

c:\\Projects\GeneralShale\2005 -0077\EmissionTestRepml Page A-8 
General Shale Brick 

Compliance Emission Test Report 

Summary of Calculations 

PM/HF EMISSION CALCULATIONS 

Run Number 

Date 

Start Time 

Time 

Run Time, rain 

Barometric Pressure, in. Hg 

Meter Correction Factor 

Orifice Calibration Value 

Meter Volume, 

Meter Temperature, °F 

Meter Orifice Pressure, in. H20 

Volume H20 Collected, mL 

Nozzle Diameter, in 

Area of Nozzle, fl^2 

Particulate Mass, mg 

Standard Meter Volume, ft 

Standard Water Volume, ft 

Moisture Fraction (Measured) 

Meter Pressure, in Hg 

Volume at Nozzle, ft•'3 

Isokinetic Sampling Rate, (%) 

Run Run 2 

2/23/2005 2/23/2005 

2:01 PM 3:40 PM 

3:07 PM 4:46 PM 

Run 3 Average 

2/23/2005 

5:IOPM 

6:13 PM 

((9) 60 60 60 60 

(Pb) 30.21 30.21 30.21 30.21 

(Y) 1.008 1.008 1.008 1.008 

(Delta H@) 1.968 1.968 1.968 1.968 

(Vm) 37.087 35.745 36.608 36.480 

(Tin) 70.3 72.7 71.5 71.5 

(Delta H) 1.383 1.258 1.325 1.322 

(Vlc) 75.6 65.4 73.4 71.5 

(Dn) 0.350 0.350 0.350 0.350 

(An) 0.00067 0.00067 0.00067 0.00067 

(Mn) 72.3 63.7 105.9 80.6 

0.9 1.1 0.9 1.0 

(Vmstd) 37.706 36.169 37.135 37.004 

(Vwstd) 3.558 3.078 3.455 3.364 

(BWS) 0.086 0.078 0.085 0.083 

(Pro) 30.31 30.30 30.31 30.31 

(Vn) 57.08 54.45 56.29 55.94 

(I) 101.0% 100.2% 101.3% 100.8% 

Particulate Concentration, grains/dscf (Cs) 0.0295 

Particulate Emission Rate, lbs/hr (PMR) 5.47 

Hydrogen Fluoride Emission Rate, lbs/hr (ER•) 0.07 

0.0271 0.0439 0.0335 

4.86 '8.00 6.11 

0.08 0.07 0:07 

c:\\Proj ects\GeneralShale\2005-0077\EmissionTestReport Page A-9 
General Shale Brick 

Compliance Emission Test Report 

Summary of Calculations 

TABLE 

HF/SO2 INLET •ATE CALCULATIONS 

Run Number 

Date 

2 3 

2/23/05 2/23/05 2/23/05 

Mean 

AP-42 Factor, lbs/ton of brick fired 

Brick Production, per hr 

Brick Weight, lbs/brick 

Fluoride Rate, Ibs/hr 

Run Number 

Date 

2 3 

2/24/05 2/24/05 2/24/05 

0.17 

8,229 

3.6 

2:52 

Mean 

Sulfur Dioxide from Gas 

AP-42 Factor, lbs/106 scf 

Conversion, % 

Gas Used, x 103 scf 

Inlet Sulfur Dioxide fi'om Gas, x 10 .3 lbs/hr 

Sulfur Dioxide from Coal 

Sulfur Content, % (dry basis) 

Coal Moisture Fraction, % 

Coal Used, lbs/hr (wet basis) 

Conversion, % 

Inlet Sulfur Dioxide from Coal, lbs/hr 

0.6 0.6 0.6 0.6 

95 95 95 95 

7.81 7.45 8.24 7.83 

4.5 4.2 4.7 4.5 

0.91 0.69 0.69 0.76 

1.61 1.73 1.78 1.71 

1,424 1,470 1,454 1,449 

95 95 95 95 

24.2 18.9 18.7 20.6 Total Inlet Sulfur Dioxide, lbs/hr 24.2 18.9 18.7 20!6 

c:\\Projects\GeneralShale\2005.0077\EmissionTestRepo1• 

Page A- 10 

2 

4 

RECTANGULAR DUC•S 

2 ,t 5 6 .7 8. '9 " 10 •I_ 12 

25.0 t6.7 12.5 10,0 8.3 7,1 &3 5.6 5,0 4•5 4.2 

75.0 50.t 37,5 •0,0 •.5.0 21.4 18,8 '16•7 15.0 13.6 12.5. 

63.3 62.5 50.0-41.7 35.7 31L3 27.8 250 22.7 20.8 

87.5 70.0 58.3 50.0 43.8 88.9 35.0. 3t,8 29.2 

90,0 75.0 64.3 56,3 50.0 45.0 40.9 37.5 

91.7 78:6-68.8 61.1 55:0 .5&O 45.8 

92,9 8•.3 72.2 65.0 59,1 54.2 

93.8 83.3 .75.0 68.2 825 

94.4 85.0 77.3 70,8 

95.0 '86.4 79.2 

95.5 87.5 

35,8 

Equfvalent diameter Dist f•'0•h'por•s• •,,×' d•i3tfi × w dth nee rest diSturba• 

depth • width • -._ 

die 

MEA.SUREMENTS 

12 

•4ETHOD" 

E. ROBERTS ALLEY&• 
DATE: 2/23/2005 

ERA&A Analyzers 

Time 02 CO2 

14:01:00 16.4 3.9 

14:02:00 16.7 3.7 

14:03:00 16.8 3.6 

14:04:00 16.3 3.9 

14:05:00 16.7 3.8 

14:06:00 16.8 3.7 

14:07:00 16.3 3.9 

14:08:00 16,6 3.8 

14:09:00 16.8 3.7 

14:10:00 16.4 3.9 

14:11:00 16.6 3,8 

14:12:00 16.8 3.7 

14:13:00 16.4 3.9 

14:14:00 16.5 3.9 

14:15:00 16.9 3.7 

14:16:00 16.5 3.9 

14:17:00 16.5 3.9 

14:18:00 16.9 3.7 

14:19:00 16.6 3.8 

14:20:00 16,5 3.9 

14:21:00 16.9 3.7 

14:22:00 16.7 3.8 

14:23:00 16.4 4.0 

14:24:00 16.8 3.7 

14:25:00 17.0 3.6 

14:26:00 16.4 4,0 

14:27:00 16.4 4.0 

14:28:00 16,8 3.8 

14:29:00 16.6 3.9 

14:30:00 16.6 3.9 

14:31:00 16.8 3.8 

14:32:00 16.9 3.7 

14:33:00 16.8 3.5 

14:34:00 16.9 3.6 

14:35:00 16.5 4.0 

14:36:00 18.7 2.5 

14:37:00 17.7 3.0 

14:38:00 16.5 4.0 

14:39:00 16.8 3.7 

14:40:00 17.0 3,5 

14:41:00 16.3 4.1 

14:42:00 16.6 3.9 

14:43:00 16.7 3.8 

14:44:00 16,5 4.0 

14:45:00 16.5 4.0 

14:46:00 16,7 3.8 

14:47:00 16.5 4.0 

14:48:00 16.6 3.9 

14:49:00 16.8 3.8 

14:50:00 16.6 3.9 

14:51:00 16.6 3.9 

14:52:00 16.8 3.8 

14:53:00 16.6 3.9 

14:54:00 16.6 3.9 

14:55:00 16.9 3.8 

14:56:00 16,6 3,9 

14:57:00 16.6 3.9 

14:58:00 16,8 3.8 

14:59:00 16.6 3.9 

15:00:00 16.5 4.0 

Uncorrected Average 

O2 16.7 % 

CO2 3,8 % 

Corrected Average 

02 16.7 % 

002 3.8 % 
DATE: 2/2312005 

ERA&A Analyzers 

Time 02 CO2 

15:40:00 17.0 3.5 

15:41:00 17.0 3.4 

15:42:00 16.4 3.9 

15:43:00 16.3 4.0 

15:44:00 16.6 3.8 

15:45:00 16.7 3.8 

15:46:00 16.4 3.9 

15:47:00 16.7 3.8 

15:48:00 16.8 3.7 

15:49:00 16.5 3.9 

15:50:00 16.7 3.8 

15:51:00 16.6 3.6 

15:52:00 16.5 3,8 

15:53:00 16.7 3.8 

15:54:00 16.9 3.6 

15:55:00 16.6 3.8 

15:56:00 16.6 3.8 

15:57:00 16.9 3,6 

15:58:00 16.5 3.9 

15:59:00 16.5 3.9 

16:00:00 16.9 3.7 

16:01:00 16.6 3.9 

16:02:00 16.5 3.9 

16:03:00 16,9 3.7 

16:04:00 16.6 3.8 

16:05:00 16.5 3.9 

16:06:00 16.9 3.7 

16:07:00 16.7 3.8 

16:08:00 16.5 3.9 

16:09:00 16.9 3.7 

16:10:00 16.8 3.8 

16:11:00 16.5 3.9 

16:12:00 16.6 3,7 

16:13:00 16.7 3.7 

18:14:00 16.5 3.7 

16:15:00 16.6 3,6 

16:16:00 16.5 3.6 

16:17:00 16.7 3.1 

16:18:00 16.9 3.7 

16:19:00 16.5 4.0 

16:20:00 16.6 3.9 

16:21:00 16,9 3.7 

16:22:00 16.6 3.9 

16:23:00 16.6 3.9 

16:24:00 16,9 3.7 

16:25:00 16.7 3.8 

16:26:00 16.6 3.9 

16:27:00 16.9 3.7 

16:28:00 16.7 3.8 

16:29:00 17.2 3.4 

18:30:00 17.1 3.6 

16:31:00 16.8 3.8 

16:32:00 16.7 3.9 

16:33:00 16.8 3.8 

16:34:00 16.7 3.8 

16:35:00 16.7 3.9 

16:36:00 17.1 3.5 

16:37:00 16.9 3.7 

16:38:00 16.4 4.0 

16:39:00 16.6 4,0 

Uncorrected Average 

02 16.7 % 

CO2 3.8 % 

Corrected Average 

02 16.7 % 

CO2 3,8 % 
DATE: 2/23/2005 

ERA&A Analyzers 

Time 02 CO2 

17:10:00 16.9 3.7 

17:11:00 17.1 3.6 

17:12:00 16.7 3.8 

17:13:00 16.9 3.8 

17:14:00 17.2 3.5 

17:15:00 16.5 4.0 

17:16:00 16.7 3.9 

17:17:00 17,0 3.7 

17:18:00 16.8 3.8 

17:19:00 16.7 3.9 

17;20:00 17.1 3.7 

17:21:00 16.9 3.8 

17:22:00 16.7 3.8 

17:23:00 17.1 3.6 

17:24:00 16.9 3.7 

17:25:00 17.5 3.3 

17:26:00 17.2 3.5 

17:27:00 16.8 3.8 

17:28:00 16.8 3.8 

17:29:00 16.9 3.7 

17:30:00 16.9 3.7 

17:31:00 16.8 3.8 

17:32:00 17.3 3.4 

17:33:00 16,8 3.8 

17:34:00 16.7 3.8 

17:35:00 16.9 3.7 

17:36:00 16.9 3.7 

17:37:00 16.9 3.7 

17:38:00 17,0 3.7 

17;39:00 17.0 3.7 

17:40:00 17.0 3.6 

17:41:00 17.0 3.6 

17:42:00 17.0 3.6 

17:43:00 16.9 3.5 

17:44:00 16.8 3.6 

17:45:00 16.8 3.6 

17:46:00 16.9 3.5 

17:47:00 16.9 3.5 

17:48:00 17.0 3.6 

17:49:00 17,1 3.5 

17:50:00 17.0 3.6 

17:51:00 16.9 3.6 

17:52:00 17.1 3.5 

17:53:00 17.0 3.6 

17:54:00 16.9 3.6 

17:55:00 17.1 3.5 

17:56:00 17,0 3.6 

17:57:00 17.0 3.6 

17:58:00 17.1 3,5 

17:59:00 17.0 3.6 

18:00:00 17,0 3.6 

18:01:00 17.1 3.5 

18:02:00 17.0 3.6 

18:03:00 17.0 3.5 

18:04:00 17.1 3.5 

18:05:00 17.0 3.6 

18:06:00 17.1 3.5 

18:07:00 17.1 3.5 

18:08:00 17.0 3.6 

18:09:00 17.0 3.6 

Uncorrected Average 

02 17.0 % 

CO2 3.6 % 

Corrected Average 

02 17.0 % 

CO2 3,6 % 
Location: General Shale- Roanoke, Virginia 

Date: 02/23/05 

Start Time: 2:01 PM 

End Time: 3:07 PM 

Source Kiln Scrubber Run 1 

Project No. 2005-0077 

STACK DATA (EST) 

% Moisture: 

Barometric: 

Static Press: 

Stack Press: 

%CO2: 3.4 

%02: 16.6 

%N2/CO: 80.0 

Md: 29.21 

Ms: 28.37 

Sample Time 

"• (minutes) 

Begin End 

A1 0.0 5.0 

2 5.0 10.0 

3 10.0 15.0 

4 15.0 20.0 

5 20.0 25.0 

6 25.0 30.0 

B1 30.0 35.0 

2 35.0 40.0 

3 40.0 45.0 

4 45.0 50.0 

5 50.0 55.0 

6 55.0 60.0 

60.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

7.5 % est. 

30.21 in Hg 

0.11 in H20 

30.22 in Hg 

% 

% 

% 

Ib/ib-mole 

Ib/Ib-mole 

Dry Gas Meter 

Reading (ft 3) 

990.628 

993.837 

996.942 

999.975 

1003.108 

1006.142 

1009.242 

1012.179 

1015.343 

1018.428 

1021.480 

1024.653 

1027.715 

1027.715 

EQUIPMENT 

METER BOX: 1376 

Y: 1.008 

DH@: 1.968 in HzO 

PITOT ID: P-11 

Cp: 0.84 

STACK DATA (EST) 

Est. Tm: 80 °F 

Est. Ts: 276 °F 

Est. dP: 0.13 in H20 

Est. Dn: 0.375 inches 

E. Roberts Alley & Associates, Inc. 

Method 5/26A Isokinetic Data 

LEAK CHECKS MOISTURE DATA 

NOZZLE ID: G-07 

Dn: 

Pre Mid 

0.350 in Leak Rate 0.001 N/A 

Diameter: 65.3 in Pump Vacuum 12 N/A 

StackArea: 23.22 ft Pitot Tube P N/A 

Pitot Gas Temperatures (°F) Orifice Press. Pump 

DP DGM DH (in H20 Vac. 

(in. H20: Inlet Outlet Stack Ideal Actual (in Hg) 

0.13 70 69 272 1.46 1.46 2 

0.13 64 69 277 1.44 1.44 2 

0.12 65 68 278 1.33 1.33 3 

0.13 68 68 279 1.44 1.44 3 

0.12 71 69 279 1.33 1.33 3 

0.12 73 72 279 1.34 1.34 3 

0.12 71 71 275 1.34 1.34 3 

0.13 73 70 277 1.45 1.45 3 

0.12 74 70 278 1.34 1.34 3 

0,12 75 70 279 1,34 1.34 3 

0.13 76 70 279 1.45 1.45 3 

0.12 71 71 279 1.34 1.34 3 

Post 

0.000 cfrn 

3 in Hg 

P P/F 

Liquid Vol. (ml) 

60 

Silica Gel (mg) 

15.6 

Gas Temps K FACTOR= 11.353 

(°F) Imp. % ISO 

Vs 

Probe Filter Exit (fps) 

254 262 51 101.2 23.93 

246 259 38 98.8 24.01 

247 261 37 100.5 23.08 

232 245 40 99.5 24.04 

235 247,[,. 44 99.9 23.10 

234 245 47 101.6 23.10 

230 245 52 96.3 23.03 

236 249 58 99.7 24.01 

236 247 50 101.1 23.08 

237 247 53 100.0 23.10 

235 244 54 99.8 24.04 

254 256 56 100.6 23.10 

Run Time 

60.0 min 

Vlllst 

Vm DP (H20) Tm Ts 

1.050 m 3.15 mm 21.3 °C. 136.4 °C 

37.087 ft 0.12 in 70.3 °F 277.6 °F 

Vw•to %HzO Qsd Qsw 

1.068 dscm 0.101 sere (meas.) 613 dscmm[ 

37 70••_•• 21,631 dscfm • 

Max DH (H20) Vs 

%ISO 

Vac. 35.137 mm 7.16 mls 

3 1.383 ill 101.0 23.49 ft/s 

Qa Y-check 

670 scmm 927 acmm 

n nOlo 

23,666 scfm 32,735 acfm 

Test Te•am/Leader •signature/date) 

Location: General Shale Roanoke, Virginia 

Date: 02/23/05 

Start Time: 3:40 PM 

End Time: 4:46 PM 

STACK DATA (EST) EQUIPMENT 

% Moisture: 8.6 % est. 

Barometric: 30.21 in Hg 

Static Press: 0.11 in H20 

Stack Press: 30.22 in Hg 

%CO2: 3.4 % 

%02: 16.6 % 

%N2/C0: 80.0 % 

Md: 29.21 lb/lb-mole Diameter 

Ms: 28.24 Ib/lb-mole Stack Area 

Sample Time Dry Gas Meter Pitot 

'• (minutes) DP 

• Reading (ft 3) 

Begin End (in. H20 

A1 0.0 5.0 1027.842 0.12 

2 5.0 10.0 1030.850 0.13 

3 10.0 15.0 1033.993 0.12 

4 15.0 20.0 1037.030 0.11 

5 20.0 25.0 1039.952 0.10 

6 25.0 30.0 1042.684 0.11 

B1 30.0 35.0 1045.640 0.12 

2 35.0 40.0 1048.724 0.I1 

3 40.0 45.0 1051.650 0.12 

4 45.0 50.0 1054.722 0.12 

5 50.0 55.0 1057.763 0.12 

6 55.0 60.0 1060.800 0.10 

60.0 1063.587 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

Final DGM: 1063.587 

METER BOX: 1376 

Y: 1.008 

DH@: 1.968 in H20 

PITOT ID: P-11 

Cp: 0.84 

Source Kiln Scrubber Run 2 

Project No. 2005-0077 

NOZZLE ID: G-07 

Dn: 0.350 in 

STACK DATA (EST) 

Est. Tm: 70 °F 

Est. Ts: 278 °F 

Est. dP: 0.12 in H20 

Est. Dn: 0.386 inches 

LEAK CHECKS 

E. Roberts Alley & Associates, Inc. 

Method 5/26A Isokinetic Data 

Pre Mid 

Leak Rate 0.000 N/A 

65.3 in Pump Vacuum 5 N/A 

23.22 ft Pitot Tube P N/A 

Gas Temperatures (°F) Orifice Press. Pump 

DGM DH (in H20) Vac. 

Inlet Outlet Stack Ideal Actual (inHg) 

72 72 278 1.31 1.31 2 

73 73 279 1.42 1.42 2 

75 73 280 1.32 1.32 2 

75 74 281 1.21 1.21 2 

75 72 280 1.10 1.10 2 

73 71 280 1.20 1.20 2 

72 72 277 1.32 1.32 3 

72 72 280 1.20 1.20 3 

73 72 280 1.31 1.31 3 

73 71 281 1.31 1.31 3 

74 71 281 1.31 1.31 3 

74 71 280 1.09 1.09 2 

MOISTURE DATA 

Liquid Vol. (ml) 

61 

Post 

0.000 cfm 

3 in Hg Silica Gel (mg) 

P P/F 5.4 

Gas Temps K FACTOR 10.910 

(°F) Imp. % ISO Vs 

Probe Filter Exit (fps) 

261 259 44 99.6 23.13 

258 252 40 99.9 24.09 

259 252 44 100.3 23.16 

258 250 46 100.7 22.19 

259 250 48 98.9 21.15 

259 250 50 102.3 22.18 

258 250 51 102.0 23.12 

256 250 51 101.3 22.18 

259 250 50 101.7 23.16 

258 260 50 100.9 23.18 

260 250 51 100.6 23.18 

254 250 51 101.0 21.15 

Vm DP (H20) Tm 

Run Time 1.012 m 2.92 mm 22.6 °C 

60.0 min 35.745 ft 0.11 in 72.7 °F 

Vms,d Vws %H20 Qsd.__•___ 

1.024dscm 0.089scm • 591dscmmJ 3• •.••- 20,879 dscfm .[ 

T••gnatm'e/d ate) 

Ts Max DH(H20) Vs 

137.6 °C Vac. 31.962mm 6.89m/s 

279.8 °F 3 1.258 in 100.3 22.60ft/s 

Qsw Qa Y-check 

0.8% 643 scmm 892 acmm 
LLI 
Location: General Shale Roanoke, Virginia 

Date: 02/23/05 

Start Time: 5:10 PM 

End Time: 6:13 PM 

Source Kiln Scrubber Run 3 

Project No. 2005-0077 

STACK DATA (EST) 

% Moisture: 8 % est. 

Barometric: 30.21 in Hg 

Static Press: 0.11 in H20 

Stack Press: 30.22 inHg 

%CO2: 3.4 % 

%O2: 16.6 % 

%N2/CO: 80.0 % 

Md: 29.21 lb/Ib-mole 

Ms: 28.31 Ib/lb-mole 

Sample Time [Dry Gas Meter 

'• (minutes) • Reading (ft 3) Begin End 

A1 0.0 5.0 1063.718 

2 5.0 10.0 1066.750 

3 10.0 15.0 1069.920 

4 15.0 20.0 I073.085 

5 20.0 25.0 1076.152 

6 25.0 30.0 1079.096 

B1 30.0 35.0 1082.268 

2 35.0 40.0 1085.312 

3 40.0 45.0 1088.484 

4 45.0 50.0 1091.647 

5 50.0 55.0 1094.723 

6 55.0 60.0 1097.552 

60.0 1100.326 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

0.0 

Final DGM: 1100.326 

EQUIPMENT 

METER BOX: 1376 

Y: 1.008 

DH@: 1.968 inH20 

PITOT ID: P-11 

Cp: 0.84 

NOZZLE ID: G-07 

Dn: 0.350 in 

Diameter: 65.3 in 

StackArea 23.22 ft 

PRO; 

STACK DATA (EST) 

Est. Tin: 73 °F 

Est. Ts: 280 °F 

Est. dP: 0.11 in H20 

Est. Dn: 0.392 inches 

E. Roberts Alley & Associates, Inc. 

Method 5/26A Isokinetic Data 

LEAK CHECKS 

Mid Post 

N/A 0.000 cfm 

N/A 3 in Hg 

N/A P P/F 

MOISTURE DATA 

ere 

Leak Rate 0.000 

Pump Vacuum 5 

Pitot Tube P 

Gas Temperatures (°F) Orifice Press. 

Liquid Vol. (ml) 

55 

Silica Gel (mg) 

18.4 

Pump Gas Temps K FACTOR= 11.045 

DP DGM DH (in Hz0) 

(in. HzO• Inlet Outlet Stack Ideal Actual 

0.12 70 70 278 1.32 1.32 

0.13 71 70 279 1.43 1.43 

0.13 72 70 280 1.43 1.43 

0.12 73 70 280 1.32 1.32 

0.11 73 70 281 1.21 1.21 

0.13 74 70 280 1.44 1.44 

0.12 70 70 278 1.32 1.32 

0.13 73 70 279 1.44 1.44 

0.13 74 70 279 1.44 1.44 

0.12 74 71 280 1.33 1.33 

0.10 74 71 280 1.!l 1.11 

0.10 74 71 279 1.11 1.11 

Vac. (°F) Imp. % ISO 

Vs 

(in Hg) Probe Filter Exit (fps) 

3 255 249 52 100.2 23.10 

3 257 250 45 100.6 24.06 

3 258 254 44 100.5 24.08 

3 257 259 44 101.2 23.14 

3 260 255 46 101.5 22.17 

3 254 255 45 100.5 24.08 

3 257 253 43 100.6 23.10 

3 259 253 42 100.5 24.06 

3 257 255 42 100.1 24.06 

3 255 251 43 101.3 23.14 

3 256 249 43 102.0 21.12 

3 261 251 41 100.0 21.11 

Vm DP (H20) Tm Ts 

Run Time 1.037 m 3.04 mm 21.9 °C 137.5 °C 

60.0 min 36.608 ft 3 0.12 m 71.5 °F 279.4 °F 

VWstd %H20 

0,098 scm (meas.) 602 dscmm 

_3.4•SS•sef o•,•. 8.5 21,246 dscfm 

Max DH (H20) 

%ISO 

Vac. 33.655mm 

3 1.325 in 101.3 

Qs•v Qa 

657 scmm 912 acmm 

23,219 scfm 32,196 acfm 

Ws 

7.04 m/s 

23.11 ft/s 

Y-check 

0.8% 

Test•Tea• Leader \-/(signature/date) 

GENERAL SHALE 

BOILER 

RUN t 

DATE: 2/24/2005 

ERA&A Analyzers 

Time 02 CO2 NOX SO2 

8:07:00 16.2 3.8 75.3 70.2 

8:08:00 16.3 3.7 78.3 69.5 

8:09:00 16.2 3.8 74.9 69.6 

8:10:00 16.2 3.8 76.8 70.0 

8:11:00 16.4 3.7 81.5 68.8 

8:12:00 16.2 3.8 75.4 68.1 

8:13:00 16.3 3.7 72.3 68.7 

8:14:00 16.4 3.6 69.2 66.4 

8:15:00 15.9 4.0 69.4 68.1 

8:16:00 16.3 3.7 82.8 69.0 

8:17:00 16.3 3.7 82.2 67.0 

8:18:00 16.1 3.8 66.6 68.9 

8:19:00 16.8 3.4 64.6 65.0 

8:20:00 16.6 3.5 65.0 62.5 

8:21:00 15.8 4.1 66.2 67,3 

8:22:00 16.1 3.9 76.4 70.4 

8:23:00 16.3 3.8 81.7 67.9 

8:24:00 16.0 3.9 70.4 68.3 

8:25:00 16.4 3.7 59,6 69.1 

8:26:00 16.4 3.7 64.7 64.4 

8:27:00 15.8 4.1 67.9 68.6 

8:28:00 16.1 3.9 73.6 72.0 

8:29:00 16.3 3.8 81.4 69.6 

8:30:00 16.0 3.9 73.9 69.0 

8:31:00 16.5 3.7 66.1 69.7 

8:32:00 16.2 3.9 76.1 66.5 

8:33:00 16.0 4.0 74.5 69.0 

8:34:00 16.0 4.0 74.3 71.8 

8:35:00 16.4 3.8 83.5 70.2 

8:36:00 16.1 3.9 78.3 68.7 

8:37:00 16.0 4.0 74.3 70.7 

8:38:00 16.4 3.7 81.8 70.1 

8:39:00 16.2 3.8 75.9 68.7 

8:40:00 16.0 3.9 70.3 70.7 

8:41:00 16.4 3.7 80,6 69.7 

8:42:00 16.3 3.8 78.0 67.1 

8:43:00 16.4 3.8 65.2 68.4 

8:44:00 16.4 3.6 79.6 62.8 

8:45:00 16.3 3.8 77.6 66,5 

8:46:00 16.0 4.0 69.3 69.0 

8:47:00 16.3 3.8 79,8 69.6 

8:48:00 16.3 3.8 80.8 67.4 

8:49:00 15.9 4.0 71.3 68.9 

8:50:00 16.3 3.9 79.9 70,0 

8:51:00 16.3 3.8 81.2 68.4 

8:52:00 15.9 4.1 71.9 70.2 

8:53:00 16.2 3,9 81.5 71.0 

8:54:00 16.3 3.9 84.8 68.9 

8:55:00 15.9 4.0 74.7 69.9 

8:56:00 16.2 3.9 79.6 70.9 

8:57:00 16.4 3.8 82.8 68,3 

8:58:00 16.0 4.0 73.5 68.5 

8:59:00 16.2 3.9 77.9 69.6 

9:00:00 16.4 3.8 83.4 67.0 

9:01:00 16.0 3.9 74.9 67.0 

9:02:00 16.2 3.9 78.0 68.6 

9:03:00 16.4 3.7 83.3 66.7 

9:04:00 16.1 3.9 75.0 66.7 

9:05:00 16.2 3,9 76.6 69.0 

9:06:00 16.4 3.7 83.4 67.1 

Uncorrected Average 

02 

CO2 

NOX 

SO2 

16.2 

3,8 

75.5 

68.5 

% 

% 

ppmvd 

ppmvd 

Corrected Average 

02 

CO2 

NOX 

S02 

16.3 

3.6 

75.4 

68.7 

% 

% 

ppmvd 

ppmvd 

1-1 
GENERAL SHALE 

BOILER 

RUN 2 

DATE: 2/24/2005 

ERA&A Analyzers 

Time 02 CO2 NOX SO2 

9:49:00 16.2 3.9 75.2 70.8 

9:50:00 16.2 4.0 76.4 72.8 

9:51:00 16.2 3.9 77.1 74.1 

9:52:00 16.2 3.9 77.0 75.3 

9:53:00 16.2 3.9 77.2 71,7 

9:54:00 I6.2 4.0 77,3 72.3 

9:55:00 16.4 3.9 80.8 72.0 

9:56:00 16,2 3.9 78.0 70,9 

9:57:00 16.2 4.0 76.8 72.0 

9:58:00 16.3 3.9 80.1 72,6 

9:59:00 16.3 3.9 77.5 71,6 

10:00:00 16.2 3.9 76.8 72.4 

10:01:00 16.3 3.9 80.5 72.3 

10:02:00 16.3 3.8 79.5 70.7 

10:03:00 16,2 3.9 77.2 71.2 

10:04:00 16.3 3.8 79.9 71.0 

10:05:00 16.3 3.8 80.2 70.2 

t0:06:00 16.5 3.7 67.6 70.1 

10:07:00 16.1 3.9 67.7 70.2 

10:08:00 16.4 3.9 82.9 71.1 

10:09:00 16.4 3.8 83.1 70.0 

10:10:00 16.5 3.7 63.8 69.9 

10:11:00 16.7 3.5 64.3 66.5 

10:12:00 16.4 3.8 71.0 65.7 

10:13:00 15.9 4.1 69.5 70.9 

10;14:00 16.3 3,9 78.2 72,3 

10:15:00 16.4 3.8 82.7 69.5 

10:16:00 16.0 4.0 72.1 69.8 

10:17:00 16.8 3.5 58.3 70,2 

10:18:00 16.2 3.9 64.5 64,9 

10:19:00 15.9 4.1 70.9 71.4 

10:20:00 16.1 4.0 77.5 73,9 

10:21:00 17.1 3.3 71.9 60.7 

10:22:00 16.1 4.0 74.9 70,4 

10:23:00 16,1 4.0 77.0 73.4 

10:24:00 16.5 3.8 85,3 71,1 

10:25:00 16.2 3.9 76.2 70.4 

10:26:00 16.2 4.0 76.0 73.5 

10:27:00 16.5 3.7 84.5 71.3 

10:28:00 16.3 3.9 79.2 70.2 

10:29:00 16.2 3.9 75.4 72.8 

10:30:00 16.6 3.7 83.1 70.7 

10:31:00 16.4 3.8 78.8 68.5 

10:32:00 16.2 3•9 73.7 70.8 

10:33:00 16.6 3.7 83.6 69.5 

10:34:00 16.5 3.7 80,0 67,4 

10:35:00 16.2 3.9 71.9 69.3 

10:36:00 16.6 3.7 81,2 68.4 

10:37:00 16.5 3.7 78.9 66.5 

10:38:00 16.2 3.9 70.8 68.5 

10:39:00 16.6 3.7 81.2 68.6 

10:40:00 16.5 3.7 80.9 66.7 

10:41:00 16.1 4.0 70.5 68.3 

10:42:00 16,5 3.8 81.1 69.0 

10:43:00 16.5 3.8 81.3 66,9 

10:44:00 16.0 4,0 71.6 69.1 

10:45:00 16.4 3,9 82.8 70.5 

10:46:00 16.5 3.8 85.0 68.5 

10:47:00 16,0 4.1 73.5 69.5 

Uncorrected Average 

02 16.3 % 

CO2 3,9 % 

NOX 76.5 ppmvd 

SO2 70.2 ppmvd 

Corrected Average 

02 16.3 % 

CO2 3.7 % 

NOX 76.4 ppmvd 

SO2 70.2 ppmvd 

1-1 
GENERAL SHALE 

BOILER 

RUN 3 

DATE: 2/24/2005 

ERA&A Analyzers 

Time 02 CO2 NOX SO2 

11:22:00 16.5 3.9 83.0 69.9 

11:23:00 16.1 4.1 72.4 69.9 

11:24:00 16.3 4.0 77.1 71.4 

11:25:00 16.5 3.8 81.8 68.8 

11:26:00 16.1 4.1 72,7 68.8 

11:27:00 16.3 4.0 76.6 71.0 

11:28:00 16.5 3.9 83.3 69.0 

11:29:00 16.2 4.0 73.6 68.8 

11:30:00 16.2 4.1 74.5 71.4 

11:31:00 16.5 3.9 82.0 69.5 

11:32:00 16.2 4.0 74.8 68.8 

11:33:00 16.2 4.I 75.0 72.2 

11:34:00 16.5 3.9 85.3 70,7 

11:35:00 16.2 4.0 77.8 69.9 

11:36:00 16.1 4.1 75.4 73.1 

11:37:00 16,5 3.9 84.2 71.5 

11:38:00 16.3 4.0 78.8 69.9 

11:39:00 16.1 4.1 73.9 72.2 

11:40:00 16.5 3.9 84.4 70.8 

11:41:00 16.3 3.9 80.1 68.8 

11:42:00 16.1 4.1 72.1 70,8 

11:43:00 16.5 3.9 81.6 70.2 

11:44:00 16.4 3.9 79.2 68.6 

11:45:00 16.0 4.1 70.3 70.5 

11:46:00 16.5 3.9 81.2 70.5 

11:47:00 16.4 3.9 80.0 68.2 

11:48:00 16.1 4.1 69.7 69.9 

11:49:00 16.4 3.9 79.9 70.1 

11:50:00 16.5 3.9 81.0 67.9 

11:51:00 16,0 4.1 70.6 69.4 

11:52:00 16.4 3.9 81,4 70,2 

11:53:00 16.5 3.9 83.0 68.2 

11:54:00 16,2 4.0 67.3 69.5 

11:55:00 16.4 3.9 67.5 69,4 

11:56:00 16.3 4.0 77.1 68.8 

11:57:00 16.4 4.0 73.1 69.1 

11;58:00 17.0 3.4 63.6 60.6 

11:59:00 16,6 3,7 61.9 63.3 

12;00:00 16.2 4.1 72.0 65.2 

I2:01:00 16.1 4.1 72.8 69.2 

12;02:00 16.1 4.1 75.0 70.2 

12:03:00 16.3 4.0 80.8 69.2 

12:04:00 16,2 4.1 73.5 69.4 

12:05:00 16.7 3.7 59.6 67.4 

12:06:00 16.3 4.0 61.9 65.7 

12:07:00 15.9 4.2 68.7 69.8 

12:08:00 16.1 4.1 73.4 71.2 

12:09:00 16.3 4.0 80.7 70.2 

12:10:00 16.1 4,1 75.6 70.2 

12:11:00 16.1 4.1 75.7 72.5 

12:12:00 16.4 4.0 82.9 71.8 

12:13:00 16.2 4.1 77.0 70.7 

12:14:00 16.1 4.1 74.9 71.6 

12:15:00 16.4 4.0 81.8 71.1 

12:16:00 16.3 4.0 77.1 69.5 

12:17:00 16.1 4.1 74.9 70.5 

12:18:00 16,4 3.9 79.6 69.9 

12:19:00 16.4 3.9 76,0 67.9 

12:20:00 16.2 4.0 73.0 68.7 

12:21:00 t6.5 3.9 78.9 68.6 

Uncorrected Average 

02 16.3 % 

CQ2 4,0 % 

NOX 75.9 ppmvd 

SO2 69.5 ppmvd 

Corrected Average 

02 16.3 % 

CO2 3.8 % 

NOX 75.9 ppmvd 

SO2 69.4 ppmvd 

1-1 
Location: General Shale Roanoke, VA 

Date: 02/24/05 

ESTIMATED STACK DATA EQUIPMENT 

% Moisture: 8.0 % est. 1376 

Barometric: 30.05 in Hg 

Static Press: 0.10 in H20 

Stack Press: 30.06 in Hg 

%CO2: 3.6 % 

%02: 16.3 % 

%N2/CO: 80.t % 

Md: 29.23 Ib/Ib-mole 

MW: 28.33 Ib/]b-rnole 

DWELL Time 

(min) 

5.12 

5.31 102.528 

5.12 104.595 

5.12 106.502 

5.12 108.492 

5.12 110.500 

5.5O 112.501 

114.640 

116.575 

118.473 

120.602 

122.512 

124.625 

5.31 

METER BOX: 

Y: 1.008 

AH@: 1.968 in H20 

Cp': 0.84 SIN 20174 

Cp: 0.84 SIN 20174 

Nozzle Dia: 

Stack Area: 

# of Points: 

Total Run Time: 

Dry Gas Pitot 

Meter AP 

Reading (ft 3) ("H201 

100.499 0.130 

0.140 

0,130 

0.130 

0.130 

0.130 

0.150 

0.140 

0.130 

0.130 

0.130 

0.140 

5.12 

5.12 

5.12 

5.31 

Start Time: 

End Time: 

0.264 inches 

23.22 • 

12 points 

60 min 

Gas Temperatures (°F', 

DGM 

ln!et...i outlet Stack 

8:07 AM RUN No. t 

9:12 AM JOE] No. 2005-0077 

ESTIMATED DATA • PMo•I 0 Mass 

Ts(°F)••mm •: 70 •11 Particulate Catches m----• 

E• 0.61t cfm 

• 

• Filterable Filter/P&N 26 

Est. •: • mpoise• Organic Imp MeCI2 0.0 

Est. AH: 0.574 ("H20) •_ inorganic 

LEAK CHECKS FINAL CATCH 

DGM initial 100.4•6 N/•- Liquid Vol. (ml) 

DGM final 100.458 N/A 

Leak Rate 0.002 N/A 

Vacuum 10 N/A 

Orifice Press. Pump 

AH (in H20) Vac. 

ideal Actual (in 

0,575 1.0 

0,575 1.0 

0.575 2.0 

0.575 2.0 

0.575 2.0 

0.575 2.0 

0.575 2.0 

0.575 2.0 

0.575 2.0 

0.575 2.0 

0.575 3.0 

0.575 3.0 

0.574 

0.574 

0,574 

0.574 

0.574i 

0.574i 

0.574 

0.574 

0.574 

0.574 

0.5741 

0.574 

124.688 cf 

t24.688 cf 

0 cfm 

3 in. Hg 

Gas Temps 

(°F) Imp 

43,3 

Y-check 

-3.2% 

Qs Dso(,m: 

(acfm} 

0.615 9.96 

0.6051 10.11 

0.579 10.46 

0.604 10.15 

0.6121 10.08 

0.604 10.12 

0.601 10.12 

0.558 10.64 

0.571 10.52 

0.842 9.71 

0.578 10.49 

0.616 10.02 

Run Time 

62.4 min 

Vmstd 

0.6944 dscm 

24,521 dscf 

Vm AP (H20) Tm Ts 

0.683 m t39.6 °C 

24.126 ft 3 283.3 °F 

Vw,ta Filterable PM-10 

0.0577 scm 0.0169 gr/dscf 

2.038 scf 3.26 Ibslhr 

3.408 mm 19,3 °C 

0.134 in 66.7 °F 

%H20 Qsd (stack) 

I(,•eas.)1638.23 dscmm 

7.•7 22,538 dscf•m 

Max AN (H20) 

Vac. 14.805 mm 

3.0 0.575 in 

Organic Condens 

Ms 

7ol,.•U 

7.484 mls 

106.5 24.553 ft/s 

inorganic Condens 

0.0000 grldscf 0.0000 grldscf 

0.00 Ibs/hr 0.00 Ibs/hr 

Final DGM: 124,625 

63.0! 63.0 280 

64.01 64.0 283 

66.01 66.0 285 

67.0 66.0 288 

66.0 65.0 287 

68.0 66.0 282 

66.0 64.0 280 

68.0 68.0 277 

68.0 68.0 282 

69.0 69.0 285 

69.01 69.0 287 

69.0 69.0 286 

Qs (acfrn): 0.597 D50 (p,m): 

Probe Filter Exit 

250 254 32 

256 255 26 

254 249 28 

256 258 28 

257 259 28 

260 258 28 

257 257 27 

260 259 28 

257 257 29 

255 258 31 

257 254 31 

258 253 31 

10.2 

Date: 02/24/05 

STACK DATA 

Location: General Shale Roanoke, VA 

% Moisture: 7.7 % est. 

Barometric: 30.05 in Hg 

Static Press: 0.10 in H20 

Stack Press: 30.06 in Hg 

%CO2: 3.6 % 

%02: t6.3 % 

%N2/CO: 80.1 % 

Md: 29.23 Ib/lb-mole 

Start Time: 9:49 AM 

End Time: 10:51 AM 

EQUIPMENT ESTIMATED DATA 

METER BOX: 1376 

Y: t.008 

•H@: 1.968 in H20 

Cp': 0.84 SIN 20174 

Cp: 0.84 SIN 20174 

Nozzle Dia: 0,264 inches 

Stack Area: 23.22 ft 

# of Points: 12 .p°ints 

Mw: 28.36 Ib/Ib-mole Total Run Time: 60 rnin 

DWELL Tirne 

RUN No. 2 

JOB No. 2005-0077 

Dry Gas 

Ts(°F): 283 Tm (°F): 67 

Est. Qs: 0.615 cfrn 

Est. •: 225.78 mpoise 

Est./•H: 0.576 ("H20) 

rEAK CHECKS 

DGM initial 124.715 N/A 147.447 cf 

DGM final 124.716 N/A 147.447 cf 

Leak Rate 0.00' N/A 0 cfm 

Vacuum 5 N/A 5 in. Hg 

Pitot Gas Temperatures (°F) Orifice Press, Purnp Gas Ternps 

PM-'i0 Mass 

Particulate Catches m====2=g 

Filterable Filter/P&N 19,7 

Organic Imp MeCI2 0.0 

Inorganic Imp Water 0.0 

FINAL CATCH 

Liquid Vol. (rnl) 

41.2 

Y-check 

-0.3% 

A/1 

2 

3 

4 

5 

6 

B/1 

2 

3 

4 

5 

6 

(rnin) 

Meter •p DGM z•H (in H20) Vac. (°F) Imp. Qs 

Reading (ft 3) ("H20) Inlet Outlet Stack Ideal Actual (in Hg) Probe Filter Exit (acfm) 

4.92 124,653 

4.75 126.714 

4.75 128.554 

4.58 130.482 

4.75 132,307 

4.75 134.190 

4.75 136.084 

4.75 137.970 

4.75 139.858 

4.58 141.738 

4.58 143.558 

4.40 145.365 

147.125 

Ds0 

0,150 "'68.0 69.0 277 0,576 0.576 3.0 258 256 26 0,639 9.67 

0,140 68.0 69.0 277 0.576 0.576 3.0 256 252 30 0.59" 10.22 

0.140 69.0 69.0 282 0.576 0.576 3.0 258 254 31 0.622 9.90 

0,130 69.0 69.0 283 0,576 0.576 3.0 256 252 31 0.612 10.03 

0.140 69.0 69.0 285 0,576 0,576 3.0 255 250 31 0.610 10.07 

0.140 68.0 68.0 285 0,576 0,576 3.0 247 253 29 0.615 10.02 

0.140 69.0 69.0 283 0.576 0.576 3.0 255 257 28 0.610 10.06 

0,140 69.0 69.0 276 0.576 0.576 3.0 253 253 29 0.605 10.04 

0,140 69.0 69.0 281 0.576 0.576 3.0 260 258 28 0.606 10.08 

0.130 70.0 69.0 283 0,576 0.576 3.0 257 264 29 0.610 10.06 

0.130 70.0 69.0 283 0.576 0,576 3.0 256 254 29 0,605 10.11 

0.120 70.0 69.0 279 0.576 0,576 3.0 257 257 30 0,610 10.01 

0.0000 ,gddscf 0.0000 gr/dscf 

0.00 Ibs/hr 0.00 Ibs/hr 

147,125 "=• Final DGM: 

Vrn /•P (H•O) Tm 

Run Tirne 0.636 rn 3 3.471 mrn 20.5 °C 

56.3 rnin 22.47t ft 3 0,137 in 69.0 °F 

Vmstd VWstd %H•O Qsd (stack) 

0.6439 dscm 0.0549 scm (meas.) 643,82 dscrnm 

22.740 dscf 1.939 scf 7.9 22,735 dscfrn 

0.0133 gddscf 

2.60 Ibsfhr 

Qs (acfm): 0.6t 3 £)50 (•m): 1 0.0 

Ts Max /•H (H•O) Vs 

%1SO 

138.4 °C Vac. 14.630 rnnrn 7.542 rnls 

281.2 °F 3.0 0.576 in 108.5 24.744 ft/s 

Fiiterable PM-10 Organic Condens Inorganic Condens 
@ 
Location: General Shale Roanoke, VA 

Date: 02124105 

ESTIMATED STACK DATA 

% Moisture: 7.9 % est, 

Barometric: 30.05 in Hg 

Static Press: 0.10 in H20 

Stack Press: 30.06 in Hg 

%CO2: 3.6 % 

3 

4 

5 

6 

B/1 

2 

3 

4 

5 

EQUIPMENT 

METER BOX: t376 

Y: 1.008 

/•H@: 1.968 in 

Cp': 0.84 SIN 20174 

Cp: 0.84 SIN 20174! 

%02: 16.3 % Nozzle Dia: 

%N2/CO: 80.1 % StackArea: 

Md: 29.23 Ib/Ib-mole • of Points: 

Mw: 28.34 Ib/Ib-mole Total Run Time: 

Dry Gas Pitot 

DWELL Time Meter 

(rain) 

Start Time: t 1:22 AM 

End Time: 12:24 PM 

ESTIMATED DATA 

RUN No. 3 

JOB No. 2005-0077 

Ts (°F): 28t Tm (°F): 69 

Est. Qs: 0.613 cfm Filte•able 

Est. •: 225.08 mpoise Organic 

Est. •H: 0,575 ("H20) Inorganic 

Reading (ft 3) 

LEAK CHECKS 

0.264 inches DGM initial 147.447 N/A 

23.22 •"•====• DGM final 147.447 N/A 

12 points Leak Rate 0 N/A 

60 min Vacuum 5 N/A 

•;as Temperatures (°F) Orifice Press. Pump 

DGM /kH (in H20) Vac. 

PM-'i 0 Mass 

Particulate Catches 

171.868 cf 

0 cfm 

3 in. Hg 

Gas Temps 

(°F) 

mg 

Filter/P&N 27.0 

Imp MeCI2 0.0 

Imp Water 0.0 

FINAL CATCH 

5,24 147.490 

5,05 149.566 

5.05 

5.24 

5.05 

5.05 

5.24 

5.24 

5.05 

5.05 

5.05 

151.553 

153.518 

155.595 

157.581 

159,553 

161.665 

163,760 

165.764 

167.738 

5.24 169,755 

171.848 

Final DGM: 171,848 

6'1.6 rain 124.358 •3 

Vmstd VWstd 

0.6982 dscm 0.0603 scm 

24,657 dscf 2,128 scf 

("H20) Inlet Outlet Stack Ideal Actual (in Hg) Probe 

0,140 69.0 •9.0 278 0.575 0.575 2.0 254 

0.130 67,0 68.0 278 0.575 0.575 2.0 256 

0.130 67.0 68.0 278 0.575 0,575 2.0 255 

0.140 69.0 69.0 282 0.575 0.575 2.0 256 

0.130 69.0 69.0 285 0.575 0,575 2.0 254 

0,130 69.0 69.0 284 0.575 0.575 2.0 258 

0.140 68.0 68.0 285 0,575 0,575 2.0 255 

0.140 68.0 68.0 272 0.575 0.575 2.0 254 

0.130 70.0 69,0 279 0,575 0.575 2.0 256 

0,130 70.0 70.0 282 0.575 0.575 3.0 257 

0.130 70.0 70.0 282 0.575 0.575 3.0 251 

0.140 69.0 69.0 281 0.575 0.575 3.0 257 

Vm •,P (H20) Tm 

Run Time 0,690 m 

Liquid Vol. (ml) 

45.2 

Y-check 

-1.0% 

Qs (acfrn): 0.608 

Ts Max z•H (H20) 

138.1 °C Vac. 14.605 mm 

280.5 °F 2.0 0.575 in 

3.408 mm 20.4 °C 

0.134 in 68.8 °F 

%H20 Qsd stack) 

(meas.) 637.68 dscmm 

J•__J22,518 dscfm L 

7.470 m/s 

108.7 24,509 ft/s 

Filterable PM-10 Organic Condens Inorganic Condens 

0.0169 gr/dscf 0.0000 gr/dscf 0.000(•, gr/dscf 

3.25 Ibs/hr 0.00 Ibs/hr 0.00 Ibs/hr 

[•50 (l•m): i 0.i 

Vs 

255 34 0.606 10.05 

253 34 0.603 10.08 

252 33 0.596 10.16 

251 33 0.609 10,05 

253 31 0.607 10.11 

253 31 0.602 10.16 

254 31 0.623 9.92 

255 31 0.607 9.96 

257 32 0.607 10.05 

255 34 0.600 10.16 

255 34 0.613 10.01 

256 34 0.613 10.00 

Filter Exit (acfm) 

Imp. Qs Ds0 (t•m) 

CYCLONIC FLOW DATA 

CL ENT e•:•#Qt 5•:I/• SOURCE I,•'l •CFU/•" PROJECT N O 

DATE i•/•3 015 ALLEY PERSONNEL •E •O.,. b,).•" ,::: DUCT DIMENSION 

AREA-•:•'i 2 PITOT ID # 72"0"? AVG COEFFC.ENT' •"•';• BAR.. PRESSURE 

SAMPLE IRUN# RUN# 

POINT ANGLE¢ •P A•GLE¢ i' AP r AN.GL.E(• AP 

 ̧25 

3O 

Cyclonic Flow E. Robel•ts Alley, & Assoc ates 
Draw North 

Arrow 

Observer's Nam• 

Qbserve.r's 

Certified by 

Date: 

. 5,70 

28• 58 o 

29 59 C) 

A si× minute 

occurred 0 

i Six minute average greater than 40% opacity• occu•tred o times. 

1.3 Th The highe.•- six b.,•iru;fe average was •._ .%. 
Visible EmisSi0n• Observation"Report. 

140 

S 

0bserver% Na .m. ! (print) 

0bserve•'s Signa[Ure: 

C.ertified by (a•eflcy)• 

L•ture •z•mtion Date: •!_,:[zL/• Fbtd EX,•n Date: •__•_•_/• 

00 00 !. I 30 0 0 0 

O 

9 @ o o O .39 ("• }0•O O 

•0 o •, • ,d 4o O..{o•O 

,. , ,.. • •.. 

-,•,,J 

•3 o o o,, o 43 O 

14 O Q O O 44 

I ,•-- 

20 o o o o O 

24 0 O O O 54 O •O•O 

260 0 0 O 06 

27 0 0 0 0t57 

28 0 58 

o 

A six minute average greater than •city 

occurred O• times, 

A six •]inute average greater •han #•aoity occuned O time•. 
stack 

Draw North 

...... Arrow 

0bserver% Nam• 

Observer's Signature: 

910 O O: O 39! 

O. O. 0 d.i 40• 

1"t O O O 41 

12 • G O.O. 42 

t3 o"•'o o 4• 

A s!i • minute average greater than •.•city occurred .O. time•. 

A •,•, m nute average greater than 

occMrred ©._ times. 

EPA Method 5 Particulate Determination Data Analysis 

Company • Shale 

Project #•- 

Test Date •/23 -.24(0_5 

# sam_ _sF Fo 

AnalystlSLJ Modell•PX 200 

Serial #•59 Certification[2/5/2004 

Sample ID 

Analysis of Particulate Recovery 

PM Run 01 PM Run 02 PM Run 03 

Filter ID 851 

Filter tare (g) 0.3692 Dates 

Final •¢. (g) 1st 0,4265 3/1/2005 

Final wt. (g) 2rid 0.4262 3/1/2005 

Net filter catch (mg) 57.2 

862 

0.3709 

0.4205 

0.4203 

Dates 

3/1/2005 

3/1/2005 

49.5 

PM2 

863 

0.3669 

0.4298 

0.4296 

62.8 

Dates 

3/1/2005 

3/1/2005 

Beaker number 

Beaker tare (g) 

Final wt. (g) st 

Final wt. (g) 2nd 

Acetone blank (g) 

Acetone vol. (mL) 

Net front rinse (mg) 

Total particulate (mg)] 

PM1 

3.7711 Dates 

3.7862 3/1/2005 

3.7864 3/1/2005 

0 

75 

15,2 

3.7665 

3.7805 

3.7809 

75 

14.2 

72.3 63.7 

Dates 

3/1/2005 

3/1/2005 

PM3 

3.8102 

3.8534 

3.8531 

.80 

43.1 

105.9 

Dates 

3/i/2005 

3/1/2005 

Sample ID 

Analysis of Particulate Recovery 

PM 10 Run 01 PM 10 Run 02 PM 10 Run 03 

Filter ID 

Filter tare (g) 

Final wt. (g) st 

Final wt, (g) 2nd 

Net filter catch (rag) 

Beaker number 

Beaker tare (g) 

Final vet, (g) 1 st 

Final wt. (g) 2nd 

Acetone blank (g) 

Acetone vol. 0nL) 

Net front rinse (rng) 

882 

0.1315 

0.1547 

0.1545 

23.1 

10-1 

3.8315 

Dates 

3/1/2005 

3/1/2005 

879 

0.1242 

0.1412 

0.1410 

16.9 

Dates 

3/1/2005 

3/1/2005 

881 

0.1219 

0.1470 

0.1467 

25.0 

Dates 

3/1/2005 

3/1/2005 

3.8353 

3.8353 

80 

3.8 

Dates 

3/1/2005 

3/1/2005 

10-2 

3.7917 

3.7944 

3.7945 

0 

75 

2.8 

Dates 

3/1/2005 

1/3/1900 

10-3 

3.7644 

3.7664 

3.7666 

80 

2.1 

Dates 

3/1/2005 

1/3/1900 

Total particulate (rag) 26.9 19.7 [ 27.0 
CLIENT INFORMATION LABORATORY INFOI:L•IAT[ON 

Attention; Jeremy Hutehens Contact: 

Client Name: E. Roberts Alley & As•oc Project: Project: 2005-0077 Date Received: 

Project Dese; (•[ •h•l• ••- Date Reported: 

Mike Challis, g,Sc, C.Chem. 

AN050181 

0 l-Mar-2005 

10-Mar-2005 

Address: 1931 Central Parkway SW, 

Suite B 

Decatur, AL 

35601 

Fax Number: 256 351-0151 

Phone Number: 256 351-012 

Submission No.: 5C0-I32 

Sample No.: 009643-009646 

NOTES: "=" not at•alysed "<' less thet• Method D•b•ction Lbtdt (MDL) 'NA no data available 

LOQ can by determined fOr all analytes b), m•l•plylng the appropriate MDL X 3,33 

SolM• dat• •s based on d• weight except for b•ta Chaises, 

Organi¢ analyses are not ¢or•ed for •raction reoove• standards •¢¢Tt for isotope 

dilu•on methods) (£¢. CA• 429 PA• all PCDD/F and DB•DBF analyses) 

The encased cop), of the C*haln of Custodj• Re•rd may contain Information a•xsary for the 

in•rp•dan of the datm 

Methods used by PSC Analytical Services are based upon those found in 'Standard Methods for the Examination of Water and Wastewateg, Twentieth Edition, Other methods arc based on the principles of MISA or EPA methodologies, New York State; ELAP Identification Number 10756, 

All work recorded herein has been done in accordance with nom•al professional standards using accepted testing methodologies, quality assurance and quality control procedures except where otherwise agreezt to by the client and testing company in writing, Any and all use of these test results shall be limited to •he actual co•t of the pertinent analysis done. There is no other warranty expressed or implied. Your samples wilt be retained at 

PSC Analytical Services for a period of three weeks from •ceipt of data or a• per contact, 

CONlVlENTS: 

(1) Matrix interference suspected 

Page of 4 

5555 NORTH SERVICE ROAD. BURLtNGTt'3i',I f3NIYttm• C'•.lxl•.r",^ •7• •u'•" 


3/lo/2oo3 Summary of AnaiyMs Pro. Dates •age MS-4 of 4 

Batch Code: 

Impknger volume measured 

Date Analysed: 

Date Prepared: 

Batch Code: 

Adjusted impinger volume 

Date Analysed: 

Date Prepared: 

Batch Code: 

Impinger Charge Volume 

Date Analysed: 

Date Prepared: 

Batch Code: 

Hydrogen Fluoride M26A 

Date Analysed: 

Date Prepared: 

0307ASA1 

009644 05 

0096•5 05 

009646 05 

05/03/07 

05/03/07 

0307ASA1 

009644 05 

009645 05 

009646 05 

05/03•7 

05/03•7 

0307ASAI 

009644 05 

009645 05 

009646 05 

05/03/07 

O5/03/07 

0307ASA4 

009643 05 

009644 05 

009645 O5 

009646 05 

05/03/07 

05/03/07 

Submission No: 5C0132 Client: E. Robcrtz Alley Assoc Project: 2005-,0077 
mmm 

O 
Appendix D •_• 
NITROGEN OXIDE EPA METHOD 7E 

INSTRUMENTAL ANALYSIS CALIBRATION DATA 

Date 2-//C'•/c T Operator 

Concentration Range Response Time 

Calibration Accuracy (Accuracy ± 2% of calibration gas value) "Z- o ppm 

Gas Cylinder Actual 

Type No. Concentration 

ZERO •' 

HIGH 

AnalyzerJ Gas Cylinder Actual Analyzer 

ZERO & SPAN SYSTEM BIAS 

GAS 

TYPE 

INITIAL 

RESPONSE 

FINAL 

RESPONSE 

ZERO 

55 .o 

GAS INITIAL FINAL 

TYPE RESPONSE RESPONSE 

ZERO (•, ? O. / 

5T.o 

(Accuracy ± 5% of span) (, "5 ppm 

(Drift ± 3% of span) 3,2 ppm 

GAS •ITI• F• 

T•E •SPONSE •SPONSE 

ZERO O. 

GAS INITIAL FINAL 

TYPE RESPONSE RESPONSE 

ZERO 

GAS INITIAL FINAL 

TYPE RESPONSE RESPONSE 

ZERO 

GAS INITIAL FINAL 

TYPE RESPONSE RESPONSE 

ZERO 
SULFUR DIOXIDE EPA METHOD 6C 

INSTRUMENTAL ANALYSIS CALIBRATION DATA 

•oo 

Calibration Accuracy (Accuracy 

Location 

Operator 

Response Time 

± 2% of span value) 

Gas Cylinder Actual 

Type No. Concentration 

ZERO 

HIGH 

ZERO & SPAN SYSTEM BIAS 

GAS INITIAL FINAL 

TYPE RESPONSE RESPONSE 

ZERO O, / 0, 'L 

• 9.4 

OAS INITIAL FINAL 

TYPE RESPONSE RESPONSE 

ZERO 6, 't_ o.'3 

d'S.Z 

:•ITI• TIME 

R• • T•ME 

GAS INITIAL FINAL 

TYPE P,£SPONSE RESPONSE 

ZERO 

lt• ,o 

! Gas Cylinder Actual Analyzer 

Type No. Concentration 

(Accuracy ± 5% of span) 7.0 ppm 

(Drift ± 3% of span) 9.% ppm 

GAS INITIM• FINAL 

TYPE RESPONSE RESPONSE 

ZERO O. 9• O. C 

•ITI• TIME 

GAS INITIAL FINAL 

TYPE RESPONSE RESPONSE 

ZERO 

:INITI• TiME 

GAS INITIAL FINAL 

TYPE RESPONSE RESPONSE 

ZERO 
OXYGEN EPA METHOD 

INSTRUMENTAL ANALYSIS CALIBRATION DATA 

Concentration Range 

Calibration Accm'acy (Accuracy 

Location 

Operator 

Response Time 

2% of span ) 

Gas Cylinder Actual Analyzer 

Type No. Concentration 

ZERO • O 0 O 

ZERO & SPAN SYSTEM BIAS 

GAS INITIAL FINAL 

TYPE RESPONSE RESPONSE 

ZERO O o O. • 

GAS INITIAL FINAL 

TYPE RESPONSE RESPONSE 

ZERO eo C, O, G 

[o .O 

GAS INITIAL FINAL 

TYPE. RESPONSE RESPONSE 

ZERO 

Gas Cylinder Actual Analyzer 

Type No. Concentration 

MID / 

(Accuracy • 5% of span) % 

(Drift + 3% of span) % ,,: ':: 

GAS INITIAL 

TYPE RESPONSE 

ZERO •. c, 

FINAL 

RESPONSE 

GAS INITIAL FINAL 

TYPE RESPONSE RESPONSE 

ZERO 

GAS INITIAL FINAL 

TYPE RESPONSE RESPONSE 

ZERO 
CARBON D•OX•DE EPA METHOD 3A 

Plant 

Date 2_ [ a.,• •o•" 

Concentration Range 

Calibration Accuracy 

tNSTRUN[ENTAL ANAL•gSIS CALIBRATION DATA 

G •.•<•t s •.. Location k-: 

Operator k 

Response Time 

(Accuracy + 2% of span) 0.5 % 

Gas Cylinder Actual Analyzer 

Type No. Concentration 

ZERO •et o.o 6 •o 

ZERO & SPAN SYS•M B•S 

GAS INITI• F• 

TYPE •SPONSE •SPONSE 

ZERO O, 3 O. % 

o .o /o. o 

GAS INITIAL FINAL 

TYPE RESPONSE RESPONSE 

ZERO O. • O. 3 

rev;ol Io. 0 /o, 0 

..•.•iVNE 

GAS •ITI• F• 

TYPE •SPONSE •SPONSE 

ZERO 

Gas Cylinder Actual Analyzer 

Type No. Concentration 

MID 1,0.0 I 0 0 

• ,.-• •,.,,.•.•.• •g• 

(Accuraw, fi% ofsp•) I.• % 

(Dfifl• 3% of span) •.$ % 

GAS INITIAL FINAL 

TYPE RESPONSE RESPONSE 

ZERO 0.3 d. 3 

•,';d 1 o. • lo. 0 

/:.... !.• :• : •:'.•."" 7 ":< 

GAS INITIAL FINAL 

TYPE RESPONSE RESPONSE 

ZERO 

GAS INITIAL FINAL 

TYPE RESPONSE RESPONSE 

ZERO 
Certificate of Ar a ys s: 

Cylinder Number: ,SG9114991 Reference Number: 

Cylinder Pressure: 1999.6 PSIG Expiration Date: 

Certification Date: 10/26/2004 Laboratory: 

Certified Concentrations 

EPA Protoco Gas Mixture 

47-124024889-5 

10126/2007 

ASG Mobile AL 

Airgas Specialty Gases 

5480 Hamilton 8oulevard 

Theodore, AL 36582 

251.653.2500 Fax: 251.653.2530 

vw•w.airgas.com 

Component Concentration Accuracy Analytical Principle Procedure 

CARBON DIOXIDE 19.87 % +/- 1% NDIR G1 

OXYGEN 20.06 % +/- 1% PARAMAGN G1 

NITROGEN Balance 

Certification performed in accordance with "EPA Traceability Protocol (Sept. 1997)" using the assay procedures listed. 

Analytical Methodology does not require correction for analytical interferences. 

DoN°tes:AirgaSnot use cy!inderPO 110747905 ,•z-•-",. be,ow 150 psig.. Approval Signature _.__•'•,_Z•_.L•z-...•_ • 

Reference Standard h'fformation 

NTRM 82659 

NTRM 82745 

Analytical Results 

st Component 

st Analysis Date: 

19.38 S 19.88 

19.88 Z 0.000 

0,000 R 19.38 

Balance Gas Component CyI.Number Concentration 

NITROGEN OXYGEN $G9163000 20.98 % 

NITROGEN CARBON DIOXIDE SG9198981- 19.37 % 

CA•ON •io•J•:Ei .::: 7., 2nd Component 

10/26/2004 1st Analysis Date: 

Z 0.000 Conc 19.87 % R 20.98 S 20.06 

R 19.38 Conc 19.87 % S 20.06 Z 0.000 

S 19.88 Conc 19.87 % Z 0.000 R 20.98 

AVG: 19.87 % 

0/26/2004 

0.000 Conc 20.06 % 

20.98 Conc 20.06 % 

20.06 Conc 20.06 % 

AVG: 20.06 % 
Certificate 

Cylinder No: 

Cylinder Pressure: 

Certification Date: 

Certified Concentrations 

of Analysis EPA Protoco Gas 

SG9136100 

2,013 psig 

01/16/2004 

Airgas Spe¢ialty 6ase8 

5480 Har•llton Blvd. 

Theodore, AL 36582 

(251) 653-2500 Fax: (251) 653-2530 

www.•irgas,com 

Mi×ture 

Reference Number: 47-76361900-004 

Expiration Date: 01/16/2007 

Laboratory: ASG- Mobile 

Certification performed in accordance with "EPA Traceability Protocol (Sept. 1997)" using the assay procedures listed. 

Analytical Methodology does not require correction for analytical interferences. 

Notes: AIRGAS PO 110853045 AIRGAS LOT# .•,-04010+,..0.,+ 

Do not use cylinder below 150 psig. 

Reference Standard information 

GMIS 0 

Analytical Results 

1st Component 

1st Analysis Date: 

R 1,026 S 

S 923.0 Z 

Z 0.0000 R 

2nd Analysis Date: 

R 1,026 S 

S 923.0 Z 

Z 0.0000 R 

Approved for Release 

01/09/2004 

923.0 Z 0.0000 Conc 923.0 PPM 

0.0000 R 1,026 Conc 923,0 PPM 

1,026 S 923.0 Conc 923.0PPM 

AVG: 923,0 PPM 

01/16/2004 

923.0 Z 0.0000 Conc 923.0 PPM 

0.0000 R 1,026 Conc 923.0PPM 

1,026 S 923.0 Conc 923.0 PPM 

AVG: 923.0 PPM 

Component Cyl. Number Concentration 

Sulfur Dioxide ND-15687 1,026 PPM 
Certificate of Analysis: 

Cylinder Number: SG9162486 

Cylinder Pressure: 1999.6 PSIG 

Certification Date: 12/27/2004 

Certified Concentrations 

Component 

NITRIC OXIDE 

NITROGEN 

EPA Protoco Gas Mixture, 

Reference Number: 

Expiration Date: 

Laboratory: 

47-124027201-1 

12/27/2006 

ASG Mobile AL 

Airgas Specialty Gases 

5480 Hamilton Boulevard 

Theodore, AL 36582 

251,653.2500 Fax: 251.653.2530 

www, airgas.com 

Concentration Accuracy Analytical Principle 

505.0 PPM +/- I% CHEMILLUM 

Balance 

Procedure 

GI 

Total oxides or nitrogen 505.0 PPM 

Certification performed in accordance with "EPA Traceability Protocol (Sept. 1997)" using the assay procedures listed. Analytical Methodology does not require correction for analytical interferenc.,es. /• 

Notes:A rgas PO 110766997 .... / /' ...*., 

Do notusecyhnderbelow ,50psig. Approval Signature &•4•b"•- • •]•1'•_•,'• /';;:'-- 

=•eference btandard Information / ,.,• • 

• ,Balance Gas •#•ponen• ••z •oncentrat•on •e• 

GMIS 0 NITROGEN NITRIC OXIDE ND17876 983 PPM 

Analytical Results 

1st Component N•(TRIG' •iB•. 

st Analysis Date: 12/17/2004 

R g83.0 S 505,0 Z 0,000 

S 505.0 Z 0.000 R 983.0 

Z 0.000 R 983.0 S 505.0 

Conc 505.0 PPM 

Conc 505,0 PPM 

Conc 505.0 PPM 

AVG: 505.0 PPM 

2rid Analysis Date: 12/2•/2004 

R 983.0 S 505.0 Z 0.000 Conc 505.0 PPM 

S 505,0 Z 0,000 R 983.0 Conc 505.0 PPM 

Z 0,000 R 983.0 S 505.0 Conc 505.0 PPM 

AVG: 505.0 PPM 
• o 

o o 

o •" 

o 

• o 
CAI Model 400 CLD NOX Analyzer 

Converter Efficiency Test 

Time Date NOx 

10:31:00 

10:32:00 

10:33:00 

10:34:00 

10:35:00 

10:36:00 

10:37:00 

10:38:00 

10:39:00 

10:40:00 

10:41:00 

10:42:00 

10:43:00 

10:44:00 

10:45:00 

10:46:00 

10:47:00 

10:48:00 

10:49:00 

10:50:00 

10:51:00 

10:52:00 

10:53:00 

10:54:00 

10:55:00 

10:56:00 

10:57:00 

10:58:00 

10:59:00 

11:00:00 

23-Feb-05 252.0 

23-Feb-05 252.1 

23-Feb-05 251.9 

23-Feb-05 251.8 

23-Feb-05 251.9 

23-Feb-05 252.0 

23-Feb-05 252.0 

23-Feb-05 252.0 

23-Feb-05 252.0 

23-Feb-05 251.9 

23-Feb-05 252.0 

23-Feb-05 252.1 

23-Feb-05 252.1 

23-Feb-05 251.9 

23-Feb-05 252.0 

23-Feb-05 252.0 

23-Feb-05 252.1 

23-Feb-05 252.1 

23-Feb-05 252.2 

23-Feb-05 252.1 

23-Feb-05 252.1 

23-Feb-05 252.1 

23-Feb-05 252.0 

23-Feb-05 252.0 

23-Feb-05 252.0 

23-Feb-05 251.9 

23-Feb-05 252.0 

23-Feb-05 252.0 

23-Feb-05 252.1 

23-Feb-05 252.1 

High: 

Low: 

Difference: 

% Efficiency: 

252.2 

251.8 

0.4 

99.8% 
Model #: C5000 

Serial #= 1376 

APEX i•STRDMENTS 

Method 

522 Series Meter Calibration 

Pre-Test Orifice Method 

English Meter Box Units, English Factor 

Filename: C:\Documents and Settings\stacyo\My Doctu•ents\Company Files\Stack Test Templates\Method Templet 

Revised! 7/25/95 Version: 

•12/22/04 

Barometric Pressure: 29.97 (in. Hg) 

Theoretical Critical Vacuum•---> 14.14 (in. 

valid test results, the Actual Vacutu•should be 1 2 in. Hg greater than the Theoretical Critical Vacuum shownabove. 

The Critical Orifice Coefficient, K', must be entered in English units, (ft)•3*(deg R)^0.5/((in. Hg)•(min)). 

DRY GAS METER READI/•GS -CRITICAL ORIFICE READINGS- 

(in H20) 

0.62 

i. I0 

1.90 

3.56 

5.50 

Vollune Vol•me Volume Initial Temps, Final Temps. Orifice Orifice Actual Ambient Temperature 

Time Initial Final Total Inlet Outlet Inlet Outlet Serial# Coefficient Vacuum% Initial Final A•erage 

(min) (cuft) (cuft) (cuft) (de F) (deg F) (deg F) (deg F) (number) (see above) (in Eg) (deg F) (deg F) (deg F) 

15.00 316.400 322.725 6.325 58.0 58.0 58.0 58.0 DG48 0.331 22,5 68.0 68.0 68.0 

i0.00 322.725 329.377 5,692 58.0 58.0 60.0 60.0 DG55 0.438 21.0 68.0 68.0 68.0 

10.00 328.377 335,436 7.059 60.0 60.0 61.0 57.0 DG63 0.562 19.5 68.0 68.0 68.0 

5.00 335.436 340.331 4.895 61.0 59.0 65.0 60.0 DG73 0,780 17.0 68.0 66,0 68.0 

5.00 340.331 346,321 5.990 65.0 60.0 68.0 61.0 DGSI 0.959 15.0 68.0 68.0 68.0 

DRY GAS ORIFICE GAS METER ORIFICE 

VOL•{E VOLU• VOLU•4E CALIBR•TION FACTOR 

CORRECTED CORRECTED CORR CORR •OMINAL Y 

Vm(std) "qm(std) Vcr(std) Vcr(std) Vcr Value Variation 

(cuft) (liters) {cuft) (liters) (cuft) (n•mber) (number) 

6.465 183.1 6.476 183.4 6.468 1,002 -0.007 

5.773 163.5 5.708 161.6 5.700 0.989 -0.020 

7.217 204.4 7.330 207.6 7.321 1.016 0.007 

5,008 141.8 5.084 144.0 5.078 1.015 0,007 

6.131 173.6 6.257 177•2 6.249 1.021 0.012 

CALIBRATION FACTOR 

Value Value ariation 

(in E20) (• M20) (in M20) 

1.895 48.13 -0.073 

1.936 49.16 -0.032 

2.029 51.53 0,061 

1.972 50.08 0.004 

2.008' 50.99 0.040 

Average 1.008 1.96• 49.98 Average 

Nete: Calibration Factor Y, the ratio of the reading of the calibration meter the dry gas meter, 

acceptable tolerance of individual values from average is +-0.02, 

Oxifice Calibration Factor d•@, the orifice differential pressure in inches of E20 that equates 0.75 cfm of air 

68 and 29.92 inches Eg, acceptable toleran • Of individual values from the average is 

/ • ,,:• .->•;.•i 

S•ED: I .,:•'• I• '-'<•''•" D•te: 

..... ?-.., • 
Sample Probe Calibratior• 

Inspected By: 

Inspection Date: 

Probe ID: 

Pitot Tube Openings Damaged? 

Pitot Tube AligmDe.nt OK? 

Calibration Required? 

External Tube Diameter (Dr)* 

*Dt must be be•wceen 3/16 abd 3/8 

Base-to-plane opening distances (Pa and Pb)* 

*Pa Pb 

Yes[ No[ 'Z" 

YeA X No[ 

Yes[ No• 

Dt 0.375 

Pa 0.4375 

Pb 0.4375 

PWDt 1.t7 

(Mustbebetween 1.05 and 1.5) 

Ifpitot does not meet the criteria specified above it must be repaired or calibrated in 

accordance with Sections 4.1.2 through 4.15 of Method 2. 

Baseline coefficient of 0.84 applied to pitots that meet inspection criteria. 

Target 

Temp. 

Reference Indicated 

Temp. Temp. 

Ice-32F 

Ambient-70F _• ,• o 

Hot Oil-150F 

Boiling H20-212F 

Hot Oil-150F 

Temp. % 

Difference Difference Specification 

% Difference < 1.5 

Comments: 

Alleg & 
Date: 

Calibrated By: 

Nozzle Calibration 

Notes: 

a: Three different nozzle diameters, each diameter must be within 0.00]" 

b: DiffD maximum difference between any two diameters 0.004 

c: D avg average of D1, D2, and D3 

ROBERTS 
Sample Probe Calibration 

Inspection Date: 

Probe ID: 

Pitot Tube Openings Damaged? 

Pitot Tube Aligmzqe.nt OK? 

Calibration Required? 

External Tube Diameter (Dr)* 

*Dr must be between 3/16 abd 3/8 

Base-to-plane opening distances (Pa and Pb)* 

*Pa Pb 

Dt 0.375 

Pa 0.4375 

Pb 0.4375 

Pa/Dt I. 17 

(Must be between 1.05 and 1.5) 

Ifpitot does not meet the criteria specified above it must be repaired or calibrated in 

accordance with Sections 4. 1,2 through 4.15 of Method 2. 

Baseline coefficient of 0.84 applied to pitots that meet inspection criteria, 

Target 

Temp. 

Ice-32F 

Ambient-70F 

Hot Oil-150F 

Boiling HzO-212F 

Hot Oil-150F 

Reference 

Temp. 

Indicated 

Temp. 

Temp. 

Difference 

0 

Difference Specification 

% Difference < 1.5 

C orrkrrlents: 
Date: 

Calibrated By: 

Nozzlle Ca•l•bratien 

Notes: 

a: Three different nozzle diame[ers, each dimneter must be within 0.001" 

b: Diff 13 maximum difference between any two diameters 0.004 

c: D avg average ofDl, D2, and D3 
Appendix E 
PROCESS DATA 

Facility: General Shale- Roanoke 

Source: Kiln Scrubber/Baghouse 

• 0.•0 • 92•.•' J i,•}•, 7,810 _[ 8,2}9 

2/24/20051 • • / •,-• • / • 
ROANOKE FEB 2005 

Run Number 

Date 

rime Began 

rime Ended 

1 2 3 Mean 

2/24/2005 2/24/2005 2/24/2005 

8:07 9:49 1:22 

9:07 t0:49 12:21 

Run Time, min 

Production Data, lbs ofbrick/hr 

Production Data, number ofbricks/hr 

Natural gas usage, scedhr 

Coal Usage, lbs/hr 

Volumetric Flow Rate, dscfm 

Nox Concentration, ppmvd 

SO2 Concentration, ppmvd 

6(} 60 60 60 

29,624 29,624 29,624 29,624 

•L229 g.229 g.229 8229 

'7.g I0 7A50 g.240 7,833 

!,424 1,470 1,454 1,449 

22,526 22,726 22,425 22,559 

75.4 76.4 75.9 75.9 

68.7 70.2 69.4 69.5 

NOx Emission Rate, lbs/hr 

SO2 Emission Rate, lbs/hr 

NOx Emission Factor, lbs/ton brick 

SO2 Emission Factor, lbs/ton brick 

NOx Emission Facotr, lbs/1000 bricks 

SO2 Emission Factor, lbs/1000 bricks 

NOx Emission Factor, lbs/ton coal 

SO2 Emission Factor, lbs/ton coal 

12.2 12.4 12.2 12.3 

15.5 15.9 15.5 15.6 

0.8 0.8 0.8 0.8 

1.0 1.1 1.0 1.1 

1.5 1.5 1.5 1.5 

1.9 1.9 1.9 1.9 

17.1 16.9 16.8 16.9 

21.7 21.7 21.4 21.6 
t5-1 

IIIYO