Entec Services, Inc 

16 D Commerce Avenue 

Hueytown, Alabama 35023 

Telephone: (205) 491-6676 

Fax: (205) 491-6614 

Results of the March 14, 2007 

Compliance Emissions Testing on the 

DIFF Baghouse Stack at the 

Borai Brick Facility in 

Union City, Oklahoma 

Submitted to: 

Boral Brick 

P.O. Box 1178 

Columbus, Georgia 31902 

Attention: Mr. Frank Porter 

Entec Project No. 27109 

Completed By: 

Report Submitted: April 11, 2007 

Reviewed By: 

Tom Lotz, Sr. 

Project Leader Technical Services Manager 

hereby certify to the best of my knowledge all field sampling and laboratory analysis performed 

for this report is authentic and accurate. It has been checked for completeness and accuracy, 
Boral Brick 

Table of Contents 

Section Paae No. 

Executive Summary 

Emissions Summary 

Detailed Test Results 

Sampling Procedures 

Location of Test Ports 

Method 26A Sampling Train 

instrument Sampling Train 

Field Data Sheets 

Test Run No. 1 

Test Run No. 2 

Test Run No. 3 

Control Room Production Data 

Original Test Protocol 

Quality Control / Quality Assurance Procedures 

QA/QC Checklist 

Meter Orifice and Temperature Check Sheet 

Fyrite Standardization 

Stratification Sheet 

Method 6C QA/QC Checklist 

Method 10 QA/QC Checklist 

1 

2 

3 

7 

11 

12 

13 

14 

15 

20 

25 

30 

33 

42 

49 

50 

51 

55 

56 

57 

Interference Checks 

Laboratory Analysis 

Gas Analyzer Calibration Data 

Analyzer Calibration Error 

System Bias and Drift 

Calibration Gas Certificates 

Equipment Calibrations 

Nomenclature and Test Calculations 

58 

60 

67 

68 

70 

74 

79 

88 
Executive Summary 

Boral Brick, located in Union City, Oklahoma, retained Entec Services, Inc. to perform 

emissions testing on the Kiln DIFF Baghouse stack. Mr. Lynn Beane and Mr. Art Otero 

of Entec Services, Inc. conducted the testing on March 14, 2007. Representing Boral 

Brick was Mr. Frank Porter who coordinated testing with the control room production 

activity. Mr. David Shultz, Mrs. Donna Lautzenhiser, and Mrs. Hillary Mosley of the 

Oklahoma Department of Environmental Quality were on site to observe the testing. 

On March 13, 2007, during preliminary evaluations, it was determined that the CO and 

SO2 levels would exceed the expected calibration gas range. Entec made 

arrangements for an additional set of calibration gas that forced testing to be pushed to 

the following day. The new calibration bottles arrived the next day and we began testing 

on March 14, 2007. No difficulties were encountered in the field collection or in the 

laboratory analysis of the samples by Entec Services, Inc. personnel. 

The emissions from the kiln are controlled by a DIFF system. The particulate emissions 

test summaries on the following pages give a detailed analysis of each test run. 

Detailed Test Results 
Entec Services, Inc. 

SOURCE OVERVIEW 

SOURCE OWNER: 

PLANT LOCATION: 

SOURCE(S) NAME(S): 

SOURCE(S) CONDITION: 

SOURCE(S) SHAPE: 

SOURCE PERMIT NUMBER: 

TEST PERFORMED: 

ADDITIONAL TEST REQUIREMENTS: 

REFERENCE METHOD TESTS: 

PROJECT MANAGER 

Boral Brick 

Union City, Oklahoma 

DIFF Baghouse Stack 

Compliance Emissions Testing 

Circular 

2004-210-0 

HCI, SO2, and CO with flow and moisture 

Subpart JJJJJ Brick MACT 

Sample Location 

Volumetric Flow 

Molecular Weight 

Moisture Content 

Sulfur Dioxide 

Carbon Monoxide 

HCI / HF 

EPA Method 

EPA Method 

EPA Method 

EPA Method 

EPA Method 

EPA Method 

EPA Method 

2 

3 

4 

6C 

10 

26A 

Mr. Tommy Lot.z, Jr. 

•ONMENTALANALYST•RO JEC'• LEA DE•tVt•-y nnBean e 

ENVIRONMENTAL ANALYST ASSISTANT Mr. Art Otero 

OWNER'S REPRESENTATIVE: Mr. Frank Porter 

RULING AGENCY: 

RULING AGENCY REPRESENTATIVE: 

RATES TESTS CONDUCTED: 

Oklahoma Department of Environmental Quality 

Mr. David Shultz, Mrs. Donna Lautzenhiser, Mrs. Hillary Mosley 

03/14/07 

ENTEC PROJECT NUMBER: 27109 
ENTEC Services, Inc. 

16-D Commerce Ave Hueytown Alabama 35023 

INPUT TEST DATA 

Client: Boral Brick Job No.: 27109 

Source: DIFF Baghouse Stack Data Input By: Art Otero 

Field Data 

Run Number 

Test Date 

Time Test Run Began Ended 

Sampling Time 

Stack Area 

'Barometric Pressure 

Stack Static Pressure 

Pitot Tube Correction factor 

Meter Correction Factor 

Meter Delta H @ 

•lozzle Diameter 

Symbol 

Pbar 

P• 

Cp 

Y 

,•H(• 

Dn 

Meter Volume Vr, 

Meter Temperature t• 

Avg. Orifice Delta H 

Impingers Weight Gain (Moisture) 

Silica Gel Impinger Weight Gain (Moisture) 

Oxygen Concentration, dry basis 

Carbon Dioxide Concentration, dry basis 

Sulfur Dioxide Concentration, dry basis 

Carbon Monoxide Concentration, dry basis 

Avg. Sq. Rt. of Delta P 

Stack Temperature 

Total Hydrogen Chloride collected, mg 

&H 

Wimp 

Units 

Military Time 

minutes 

Test Data 

in. Hg 

in. 

in. Hz0 

inches 

dcf 

t 2 3 

03/14/07 03/14/07 03/14/07 

1126-1232 

6O 

1300-1404 

6O 

1414-1517 

6O 

Ft .= 15.904 15.904 15.904 

28.87 28.87 28.87 28.87 

-0.23 

0.84 

0.986 

1.800 

0.375 

52.614 

F 71.5 

in. H20 

grams 

-0.20 

0.84 

0.986 

1.8OO 

0.375 

57.346 

78.2 

2.95 

115.0 

2.57 

110.0 

-0.25 

0.84 

0.986 

1.800 

0.375 

56.777 

80.9 

2.85 

123.0 

AVERAGE 

-0.23 

0.84 

0.986 

1.800 

0.375 

55.579 

76.9 

2.79 

116.0 

grams 13.9 15.2 11.1 13.4 

% 17.5 17.0 16.0 16.8 

CO= % 3.0 4.0 4.0 3.7 

SO2 ppm 28.4 20.4 31.1 26.64 

CO ppm 

(sqrt AP)a,• 

HCL 

88.6 

0.457 

307.5 

92.6 

0.484 

306.7 

0.81 

90.2 

1.42 

0.493 

303.0 

0.78 

(in. H20) 1/2 

F 

mg 

90.48 

0.478 

305.7 

1.00 

5 
Client: Boral Brick Job No.: 27109 

Soume: DIFF Ba•lhouse Stack Data Input By: Art Otero 

Description Formulas S]/mbol Units Calculated Data 

Run Number 2 3 AVERAGE 

Test Date 03/14/07 03/i4/07 03/14/07 iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiti!i 

Time Began-Ended 

1. Stack Pressure P•,r P;113.e 

2. Meter Pressure Pt•r &tt 13.e 

3. Standard Meter Volume 17.64*Y* (vmrrm)* (P•,x &H 113.6) 

'4a. Standard Volume of Water Vapor Condensed =o.0470e'w•m• 

4b. Standard Volume of Water Collected in Silica Gel 

5. Moisture Fraction 

9. Molecular Weight Of Stack Gas, dry basis 

:0.04719•N,• 

=(V•,•=•) V•,.•=•))/(V,•=•) V•,,i,= 

0.32*(O•)÷ 0.44"{CO.•)+0.28*(100-(0z)-(CO•) 

10. Molecular Weight Of Stack Gas, wet basis MZ(1-Bw=)÷IS.0*(B• 

11. Average Stack Gas Velocity 

12. Stack Gas Flow @ Stack Conditions 

85.49'Cp*(sqrt AP)z•*SQRT((T=) 

60*vs*A, 

13. Stack Gas Flow @ Standard Conditions Q=*(T,•J'Fs),(ps/p 

14. Stack Gas Flow @ Dry Standard Conditions Q,'(1-8•)*( T,•T,)*( Ps/P==| 

,14b. Hydrogen Chloride concentration @ Std.Cond.,Grains/Cu.Ft. 

15b. Hydrogen Chloride emissions, Ibs per hour 

:(0.01543*HCI.•)IQ=• 

16. Sulfur Dioxide (SO2) Gas Concentration =c•,, MW 385.1 10 

16. Carbon Monoxide (CO) Gas Concentration =c=,, MW/385.1 10 

21. Suffur Dioxide (SO•) Gas Concentration =csoz (:1=• so 

21. Carbon Monoxide (CO) Gas Concentration =Coo O,• s2 

22. Volume collected through nozzle =TJPs'[0.OO2eSS'V•=+ Vm*Y=Pm/Tntl! 

Ps in. Hg 28.85 28.86 28.85 28,85 

Pm in. Hg 29.06 29.09 29.08 29.08 

V•,=) dscf 50.033 53.909 53.089 52.344 

V.•==• scf 5.177 5,412 5.788 5.459 

v,,=,=• scf 0.655 0.717 0.523 0.632 

B• fraction 0.1044 0.1021 0.1063 0.1042 

Me g/g-mole 29.180 29.320 29.280 29.260 

Ms g/g-mole 28.013 28.164 28.081 28.086 

v, ft/s 31.98 34.28 33.62 33.362 

O, acrm 30,518 32,715 32,274 31,836 

Q, scfm 20,238 21,824 21,425 21,162 

• dscfm 18,125 19,597 19,148 18,957 

HCLcs grldscf 4.379E-04 2.233E-04 2.354E-04 2.989E-04 

HCl -Ibghr la$1hr 0.07 0.04 0.04 0.05 

Cwz Ibs/dscf 4.73E-06 3.39E-06 5.17E-06 4.43E-06 

C¢, Ibs/dscf 6.45E-06 6.56E-06 6.74E-06 6.58E-06 

SOz-lblhr Ib/hr 5,14 3.99 8.94 5.02 

CO-]bRir Ib/hr 7.01 7.71 7.74 7.49 

V• acf 84.243 89.998 89.484 87.908 

24. Isokinetic Sampling Rate, Percent 100*Vnl (60*v='A•*0)l % 95.40 95.07 95.82 95.43 

::::::::::::::::::::::::::::::::::: 

Post Meter Odfice Cal. (EMC ALT-00S Yqa) y= iii•iiiiiiii::i!!::i::iii::iii•iiiiiii• 1.0376 1.0237 1.0196 1.0270 

% Difference, (Calibration must be within 6% of original Y-factsr) !!i•iii!iliiiiiiii•ililiii!iiii!!!•iiiiiiiii•!•i -4.16°/o 
Sampling Procedures 
P roced u res 

The emission rates were determined using EPA Methods 1-4, 6C, 10 and 26A of CFR 

Title 40, Part 60, Appendix A. The calibration and quality assurance procedures of EPA 

CFR 40 Part 60 Appendix A for all methods, and the "Quality Assurance Handbook for 

Air Pollution Measurement System" Volume III Stationary Source-Specific Methods 

were followed throughout the duration of the field and laboratory testing. 

The most current revision revised for each method (as described in the Federal 

Register) was used. 

Stack Gas Volumetric Flow 

The velocity of the gas stream was determined according to EPA Reference Method 1 

and 2 by reading the instantaneous velocity head with an inclined manometer at each 

sampling point with a calibrated S-type pitot tube attached adjacent to the sample 

nozzle. The stack pressure was measured with the static side of an S-type pitot tube. 

A calibrated pyrometer was used to measure stack temperature at each sampling point. 

Moisture Content 

The moisture content used for calculating the gas stream flow rate was determined by 

weighing the amount of condensed moisture collected in the impingers of the sampling 

train as described in EPA Reference Method 4. 

The moisture collection system consists of a series of impingers. Ice is placed around 

the impingers. The•utlet temperature of•he impingers is monitored and recorded 

throughout the duration of the testing to verify the temperature is below <68 o 

Sulfur Dioxide Method 6C 

A Western Research Model 721M SO2 (Method 6C) analyzer provided continuous 

analysis of SO2 in the gas stream. The basic analytical principle involves quantitative 

measurement of the absorption of UV radiation by SO2 molecules. The analyzer uses a 

single light source, which emits an appropriate wavelength, illuminating the sample cell 

through which the sample is continuously passed. Narrow-band optical filters are 

rotated through the beam, and the radiation passed through the optical filters and 

sample cell is detected by a single photo-detector. The signal pulses from the photo- 
detector are separated by a multiplexor into a measuring channel and a reference 

channel. A log ratio amplifier computes the logarithm of the input signal ration, 

producing a signal that is proportional to the SO2 concentration. The dual-range 

analyzer has a digital readout, as well as 0-10.0 V DC output terminals. The full scale of 

the instrument was set at 221 ppm. 

Carbon Monoxide Method 10 

The CO emissions were measured using a Siemens Ultramat 23 analyzer. This monitor 

is a selective non-dispersive infrared radiation (NDIR) gas analyzer that operates on the 

infrared double-beam alternating light principle. The full range for the CO component of 

this instrument throughout the test period was 227 ppm. 

Sampling System 

Due to the new test requirements, a stratification test was determined. It was found 

that the gas stream was unstratified. A single point was used to collect the gas 

samples. Samples were extracted from the gas stream by a heated stainless steel 

probe maintained at a set temperature of 250 degrees Fahrenheit, through a ten (10) 

foot heated sample line that was heated to a temperature between 225 and 250 

degrees, through a chilled sample conditioner to remove the moisture in the gas stream 

and transported to the test trailer through unheated teflon sample lines to the analyzers. 

Data Acquisition 

Concentration values were collected using a STRATA data acquisition system. The 

data was recorded every fifteen-seconds and then averaged for each sixty-second 

interval. Each minute average was then averaged for the duration of each test run. 

During all testing, the unit was operating within normal operating parameters; at a range 

appropriate in accordance with applicable permits. 

Hydrogen Chloride Method 26A (HCI) 

Preliminary data was used to determine stack temperature, pressure, and range of 

velocity heads, moisture content and stack gas dry molecular weight prior to sampling. 

The meter box was leak checked from the pump to the orifice. Initial and final leak 

checks of the sampling system and pitot lines were performed as outlined in Method 5 

and were recorded on the data sheets. The nozzle (glass with an angle of taper of 30 
degrees and of button hook design) was calibrated before and after the test using a 

micrometer and was recorded on the field data sheets. 

The sampling probe was placed at each sampling point to provide a total sampling time 

of sixty (60) minutes. The gases were drawn through a glass nozzle attached to a 

heated glass lined probe. The probe was maintained at the proper settings to obtain 

an exit temperature of greater than 2480 F during sampling. The gases then proceeded 

through borosilicate glass filter holder, with a Teflon frit filter support through a Teflon 

filter to remove particulate matter. The filter was maintained at a temperature of greater 

than 248 0 F. These temperatures were recorded at each point on the field data sheets. 

The gases were then scrubbed through a series of four pre-weighed impingers to 

capture hydrogen halides and halogens and moisture. (The optional first impinger for a 

knockout for moisture was not used.) The first and second impingers contained 

approximately 100 ml of a 0.1N H2SO4 (acid) solution and the third and fourth impingers 

contained approximately 100 ml of a 0.1 N NaOH (alkaline) solution. The fifth impinger 

contained pre weighed silica gel to remove any remaining moisture. The gases pass 

through the impinger series in an ice bath to maintain a maximum exit temperature of 

68 0 F. This temperature was also recorded on the data sheets. The clean and cool 

gases then entered the meter box where the gas flow and temperature were measured. 

After the completion of the test the sampling train and the probe nozzle assembly was 

transferred to the cleanup area making sure no particulate was lost. The cleanup data 

wa•recorded. 

The first and second impinger contents were transferred to its tared container, weighed 

and the rinsing from the glassware were added to this container. The third and fourth 

impinger was transferred to its respective tared container, weighed and the rinsing from 

the glassware was added to this container. The silica gel from the fifth impinger was 

transferred to its respective tared container and weighed. A blank of the sulfuric acid 

solution, sodium hydroxide, distilled water and acetone was taken. These containers 

were clearly marked and transported to the laboratory for analysis. 
Entec Services, Inc 

16 D Commerce Ave. Hue•own AL 35023 

STACK DRAWING & TRAVERSE POINT LOCATION 

Client: Boral Brick Job No. 27109 

Source: DIFF Baghouse Stack Input By: Art Otero 

Type of Traverse: Velocity (V) or Particulate (P): P Port Type Nipple Port Diameter 4.0" 

Stack Diameter, inches: 54 Stack Area, Ft2: 15.904 

Stack Height, feat: 75 Number of Ports: 2 

Stack Properties: Inches Duct Diameters Length of Port, inches: 6.00 

Upstream Disturbance: 222.0 4.11 Total Number of Traverse Points: 12 

Downstream Disturbance: 387.0 7.17 Number of Points per diameter: 6 

54.0 •NCHES 

222.¢ NCHES 

Point N• 

Inside Stack Outside Nipple 

Inches Inches 

1 2.4 8.4 

2 7.9 13.9 

3 16.0 22.0 

4 38.0 44.0 

5 46.1 52.1 

6 51.6 57.6 

Adjusted points diameter > 24" no point closer than 1.0 inch 

Adjusted points diameter < 24" no point closer than 0.5 inch 

Stack Diameters between 12-24 inches minimum points are 8 

4 points per po•t if the 812 diameters downstream and 

upstream criteria is met. 

387.0 INCHES 

3.1 
Method 26A Sampling Train 

(<68 F) 

Te•ePn•rTe 1.0•l #3 #4 

t•SO 4aO[ •IaO[ liea G 

Exhaust •O O • • • O[ 

Controllers 

Temperature 

Pressure Dry Gas Meter 

12 
Instrument Sampling Train 

Three Way Valve 

Calibration Gas Line 

Heated'Teflon Line 

In-stack 

Filter 

Steel 

S•iniess 

Heated 

Probe • 

RemOval 

Sy•t•em 

Communication Lines 

Data 

Acquisition 

System 

Flow Control 

Panet 

0000000 

SO= 

CO 

AiP Sampling 

Analyzem 

Calibrati°n 

Gases 
EN TEC Services 

Pollution Control System Evaluation and Source Emissions Testing 

Boral Brick 

Union City, Oklahoma 

Compliance Emissions Testing 

DIFF Baghouse Stack HCI,-SO2, arid CO 

March 44, 2007 

Entec Project No.: 27109 

16-D Commerce Avenue Hueytown, Alabama 35023 Phone: (205) 491-6676 Fax (205) 491-6614 

www.entecservices.com 
Executive Summary 

Boral Brick, located in Union .City, Oklahoma, retained Entec Services, Inc. to perform 

emissions testing on the Kiln DIFF Baghouse stack. Mr. Lynn Beane and Mr. Art Otero 

of Entec Services, Inc. conducted the testing on March 14, 2007. Representing Boral 

Brick was Mr. Frank Porter who coordinated testing with the control room production 

activity. Mr. David Shultz, Mrs. Donna Lautzenhiser, and Mrs. Hillary Mosley of the 

Oklahoma Department of Environmental Quality were on site to observe the testing. 

On March 13, 2007, during preliminary evaluations, it was determined that the CO and 

SO2 levels would exceed the expected calibration gas range. Entec made 

arrangements for an additional set of calibration gas that forced testing to be pushed to 

the following day. The new calibration bottles arrived the next day and we began testing 

on March 14, 2007. No difficulties were encountered in the field collection or in the 

laboratory analysis of the samples by Entec Services, Inc. personnel. 

The emissions from the kiln are controlled by a DIFF system. The particulate emissions 

test summaries on the following pages give a detailed analysis of each test run. 

•ed Test 
Entec Services, Inc. 

SOURCE OVERVIEW 

SOURCE OWNER: 

PLANT LOCATION: 

SOURCE(S) NAME(S): 

SOURCE(S) CONDITION: 

SOURCE(S) SHAPE: 

SOURCE PERMIT NUMBER: 

TEST PERFORMED: 

ADDITIONAL TEST REQUIREMENTS: 

REFERENCE METHOD TESTS: 

Boral Brick 

-Union City, Oklahoma 

DIFF Baghouse Stack 

Compliance Emissions Testing 

Circular 

2004-210-C 

HCI, SO2, and CO with flow and moisture 

Subpart JJJJJ Brick MACT 

Sample Location EPA Method 1 

Volumetric Flow EPA Method 2 

Molecular Weight EPA Method 3 

Moisture Content EPA Method 4 

Sulfur Dioxide EPA Method 6C 

Carbon Monoxide EPA Method 10 

HCI / HF EPA Method 26A 

PROJECT MANAGER Mr. Tommy Lotz, Jr. 

•MENTAL•U•d.YS3"•_ Eynn-Beane 

ENVIRONMENTAL.ANALYST ASSISTANT Mr. Art Otero 

OWNER'S REPRESENTATIVE: Mr. Frank Porter 

RULING AGENCY: 

RULING AGENCY REPRESENTATIVE: 

•ATES TESTS CONDUCTED: 

Oklahoma Department of Environmental Quality 

Mr. David Shultz, Mrs. Donna Lautzenhiser, Mrs. Hillary Mosley 

03/14/07 

ENTEC PROJECT NUMBER: 27109 
ENTEC Services, Inc. 

16-D Commerce Ave. Hueytown0 Alabama 35023 

INPUT TEST DATA 

Client: Job No.: 27109 

Source: Data Input By: Art Otero 

Run Number 

Test Date 

Time Test Run Began Ended 

Sampling Time 

Stack Area 

Barometric Pressure 

Stack Static Pressure 

Pitot Tube Correction factor 

Meter Correction Factor 

Meter Delta H @ 

•lozzle Diameter 

Meter Volume 

Meter Temperature 

Avg. Orifice Delta H 

Impingers Weight Gain (Moisture) 

Silica Gel Impinger Weight Gain (Moisture) 

Oxygen Concentration, dry basis 

Carbon Dioxide Concentration, dry basis 

Sulfur Dioxide Concentration, dry basis 

'Carbon Monoxide Concentration, dry basis 

Avg. Sq. Rt. of Delta P 

Stack Temperature 

Total Hydrogen Chloride collected, mg 

Boral Brick 

DIFF Baghouse Stack 

Field Data Symbol 

PMr 

P• 

C•, 

Y 

&H@ 

D. 

,•H 

O2 

COz 

SO2 

CO 

(sqrt •)=v• 

HGL 

Units 

Military Time 

minutes 

Ft 

in. Hg 

in. Hz0 

in. H20 

03/14/07 

1126-1232 

6O 

15.904 

28.87 

-0.23 

0.84 

0.986 

1.800 

03/14/07 

1300-1404 

6O 

15.904 

28.87 

-0.20 

0.84 

0.986 

1.800 

Test Data 

03/14/07 

1414-1517 

6O 

15.904 

28.87 

-0.25 

0.84 

0.986 

1.800 

AVERAGE 

!iiilliiiiiiillii!i 

28.87 

0.986 

1.800 

inches 0.375 0.375 0.375 0.375 

dcf 52.614 57.346 56.777 55.579 

in. H20 

grams 

grams 

71.5 

2.57 

78.2 

2.95 

80.9 

2.85 

76.9 

2.79 

110.0 115.0 123.0 116.0 

13.9 15.2 11.1 13.4 

17.5 17.0 

3.0 

28.4 

88.6 

0,457 

307.5 

1.42 

4.0 

20.4 

90.2 

0.493 

16.0 

4.0 

.31.1 

92.6 

0.484 

306.7 

0.81 

ppm 

ppm 

(in. H20) 112 

F 

mg 

303.0 

0.78 

16.8 

3.7 

26.64 

90.48 

0.478 

305.7 

1.00 

5 
ENTEC Services, Inc. 

16-D Commerce Ave. Hue/town PJabama 35023 

CALCULA'IED TEST DATA 

Client: Boral Brick Job No.: 27109 

Source: DIFF Ba•lhouse Stack Data IrLout By: Art Otero 

Description Formulas Symbol Units Calcu:•:•. 

2 3 

Run Number 

AVERAGE 

Test Date 03114/07 03/14/07 03/14/07 • 

Time Began-Ended Military'rime 1126-1232 1300-1404 1414-1517 

1. Stack Pressure P=w÷ Pal 13.( P, in. Hg 28.85 28.86 28.85 28.85 

2. Meter Pressure P• &H 113.( P• in, Hg 29.06 29.09 29.08 29.08 

3. Standard Meter Volume 17.64*Y*(V•)Tm)° (P• &H 113.6 V,•,= dscf 50.033 53.909 53.089 52.344 

4a. Standard Volume of Water Vapor Condensed =0,0470¢'w• v,•,• scf 5.177 5.412 5.788 5,459 

4b. Standard Volume of Water Collected in Silica Gel =o.0471•'W=• u..;_, scf 0.655 0.717 0,523 0.632 

5. Moisture Fraction =(V.•.• V.,==a)p(V.,•== v•..• V,,•==) I], fraction 0.1044 0.1021 0.1063 0.1042 

9. Molecular Weight Of Stack Gas, dw basis 0.32"(0•)* 0.44"(c0•.0.28"(1oo-(0zHc0.#, I• g/g-mole 29.180 29.320 29.280 29.260 

10. Molecular Weight Of Stack Gas, wet basis I•*(1-B,•p18.0=(B•=] IV• g/g-mole 28.013 28.164 28.081 28 086 

11. Average Stack Gas Velocity 85.4s'c=*(sqrt •)•*SQRT((T,) (Ps*M.)] v= ff/s 31.98 34.28 33.82 33.362 

12. Stack Gas Flow @ Stack Conditions S0"v='A, •, acfm 30,518 32,715 32,274 31,836 

13. Stack Gas Flow @ Standard Conditions Q,*(T=a•T,)=(P=/P•) Q= scfm 20,238 21,824 21,425 21,162 

14. Stack Gas Flow @ DW Standard Conditions Qa=(1-B•)*(T•I',)°(P#P=•) Q• dscfm 18,125 19,597 19,148 18,957 

14b. Hydrogen Chloride concentration @ Std.Cond.,Grains/Cu.Ft. =(0.O1543•1C•|/Q== HCLcs gr/dscf 4.379E-04 2.233E-04 2.354E-04 2.989E-04 

15b. Hydrogen Chloride emissions. Ibs per hour =(sor/o0o)-Hm q.•*o,,• HC1.4b•h•" Jbs/hr 0.07 0.04 0.04 0.05 

16. Sulfur Dioxide (SO2) Gas Concentration =c== MW1385.1 x1¢ c,• tbs/d"=cf 4.73E-06 3.39E-06 5.17E-06 4.43E-06 

16. Carbon Monoxide (CO) Gas Concentration =c=., MWl385.1 xl0• C• Ibs/dscf 6.45E-06 6.56E-06 6.74E-06 6.58E-06 

21. Sulfur Dioxide (SO2) Gas Concentration =c=oz Q,•* 8¢ soz4u/l=r Ib/•r 5.14 3.99 5.94 5.02 

21. Cadoon Monoxide (CO) Gas Concentration --coo Q,•- 8•. CO-•b•" It•r 7.01 7.71 7.74 7.49 

22. Volume collected through nozzlo =TJP,'[0.002669"V•=+ Vm'Y'P.ff.,] V. acf 84,243 89.998 89.484 87.908 

24. Iso•inetic Sampling Rate, Percent too*vnl (6o'v,-•*e) % 95.40 95.07 95.82 95.43 

"Oat Meter Odtloe Cal, (EMC ALT-009 Yq.) iiiii •iii ::i•i• •i/[liiiii::] :::::::::::::::::::::::::::::::::::::::::: ..'..:•.•..•. ..'..E•t.,'......,....J ..'.:•.'.• 
ENTEC Services 

Pollution Control System Evaluation and Source Emissions Testing 

Borai Brick 

Union City, Oklahoma 

Compliance Emissions Testing 

DIFF Baghouse Stack HCI, S02, and CO 

March 14, 2007 

Entec Project No.: 27109 

16-D Commerce Avenue Hueytown, Alabama 35023 Phone: (205) 49t.6676 Fax (205) 491-6614 

Hfww.entecservices.corn 
Entec Services, Inc. 

16 D Commerce Avenue 

Hueytown, Alabama 35023 

Telephone: (205) 491-6676 

Fax: (205) 491-6614 

Results of the March 14, 2007 

Compliance Emissions Testing on the 

DIFF Baghouse Stack at the 

Boral Brick Facility in 

Union City, Oklahoma 

Submitted to: 

Boral Brick 

P.O. Box 1178 

Columbus, Georgia 31902 

Attention: Mr. Frank Porter 

Entec Project No. 27109 

Completed By: 

Report Submitted: April 11, 2007 

Reviewed By: 

Lynn Beane 

Project Leader 

Tom Lotz, Sr. 

Technical Services Manager 

hereby certiCy to the best of my knowledge all field sampling and laboratory analysis performed 

for this report is authentic and accurate. It has been checked for completeness and accuracy. 
Boral Brick 

Table of Contents 

Section 

Executive Summary 

Emissions Summary 

Detailed Test Results 

Sampling Procedures 

Location of Test Ports 

Method 26A Sampling Train 

Instrument Sampling Train 

Field Data Sheets 

Test Run No. 1 

Test Run No. 2 

Test Run No. 3 

Control Room Production Data 

Original Test Protocol 

Quality Control i Quality Assurance Procedures 

QA/QC Checklist 

Meter Orifice and Temperature Check Sheet 

Fyrite Standardization 

Stratification Sheet 

Method 6C QA/QC Checklist 

Method 10 QA/QC Checklist 

Pa_qe No. 

1 

2 

3 

7 

11 

12 

13 

14 

15 

20 

25 

30 

33 

42 

49 

50 

51 

55 

56 

57 

Interference Checks 

Laboratory Analysis 

Gas Analyzer Calibration Data 

Analyzer Calibration Error 

System Bias and Drift 

Calibration Gas Certificates 

Equipment Calibrations 

Nomenclature and Test Calculations 

58 

60 

67 

68 

70 

74 

79 

88 
Executive Summarv 

Boral Brick, located in Union City, Oklahoma, retained Entec Services, Inc. to perform 

emissions testing on the Kiln DIFF Baghouse stack. Mr. Lynn Beane and Mr. Art Otero 

of Entec Services, Inc. conducted the testing on March 14, 2007. Representing Boral 

Brick was Mr. Frank Porter who coordinated testing with the control room production 

activity. Mr. David Shultz, Mrs. Donna Lautzenhiser, and Mrs. Hillary Mosley of the 

Oklahoma Department of Environmental Quality were on site to observe the testing. 

On March 13, 2007, during preliminary evaluations, it was determined that the CO and 

SO2 levels would exceed the expected calibration gas range. Entec made 

arrangements for an additional set of calibration gas that forced testing to be pushed to 

the following day. The new calibration bottles arrived the next day and we began testing 

on March 14, 2007. No difficulties were encountered in the field collection or in the 

laboratory analysis of the samples by Entec Services, Inc. personnel. 

The emissions from the kiln are controlled by a DIFF system. The particulate emissions 

test summaries on the following pages give a detailed analysis of each test run. 

Detailed Test R,es ! 
Entec Services, Inc. 

SOURCE OVERVIEW 

SOURCE OWNER: 

PLANT LOCATION: 

SOURCE(S) NAME(S): 

SOURCE(S) CONDITION: 

SOURCE(S) SHAPE: 

SOURCE PERMIT NUMBER: 

TEST PERFORMED: 

ADDITIONAL TEST REQUIREMENTS: 

REFERENCE METHOD TESTS: 

PROJECT MANAGER 

••T•-PROJECT "^ n,-,• 

ENVIRONMENTAL ANALYST ASSISTANT 

OWNER'S REPRESENTATIVE: 

RULING AGENCY: 

RULING AGENCY REPRESENTATIVE: 

•ATES TESTS CONDUCTED: 

ENTEC PROJECT NUMBER: 

Boral Brick 

Union City, Oklahoma 

DIFF Baghouse Stack 

Compliance Emissions Testing 

Circular 

2004-210-C 

HCI, SO2, and CO with flow and moisture 

Subpart JJJJJ Brick MACT 

Sample Location EPA Method 1 

Volumetric Flow EPA Method 2 

Molecular Weight EPA Method 3 

Moisture Content EPA Method 4 

Sulfur Dioxide. EPA Method 6C 

Carbon Monoxide EPA Method 10 

HCI / HF EPA Method 26A 

Mr. Tommy Lotz, Jr. 

Mrs. EynnBeane 

Mr. Art Otero 

Mr. Frank Porter 

Oklahoma Department of Environmental Quality 

Mr. David Shultz, Mrs. Donna Lautzenhiser, Mrs. Hillary Mosley 

03/14/07 

27109 
ENTEC Services, Inc. 

16-D Commerce Ave. Hueytown ,•!•_b_•ma 35023 

INPUT TEST DATA 

Client: Boral Brick Job No.: 27109 

Source: DIFF Baghouse Stack Data Input By: Art Otero 

Field Data Symbol 

Run Number 

Units Test Data 

1 2 3 AVERAGE 

Test Date 

Time Test Run Began Ended 

Sampling Time 

Stack Area 

Barometric Pressure 

Stack Static Pressure 

Pitot Tube Correction factor 

Meter Correction Factor 

Meter Delta H @ 

•ozzle Diameter 

Meter Volume 

Meter Temperature 

Avg. Orifice Delta H 

Impingers Weight Gain (Moisture) 

Silica Gel Impinger Weight Gain (Moisture) 

Oxygen Concentration, dry basis 

Carbon Dioxide Concentration, dry basis 

Sulfur Dioxide Concentration, dry basis 

Carbon Monoxide Concentration, dry basis 

Avg. Sq. Rt. of Delta P 

Stack Temperature 

Total Hydrogen Chlodde collected, m 9 

Pba¢ 

C•, 

Y 

Milita W "lime 

minutes 

Ft 

in. Hg 

in. H•O 

03/14/07 

1126-1232 

6O 

15.904 

28.87 

-0.23 

0.84 

0.986 

1.800 

03/14/07 

1300-1404 

6O 

15.904 

28.87 

-0.20 

0.84 

0.986 

1.800 

03/14/07 

1414-1517 

6O 

15.904 

28.87 

-0.25 

0,986 

1.800 

D. inches 0.375 0.375 0.375 

Vm dcf 52.614 57.346 56.777 

71.5 78.2 80.9 

2.57 2.95 2.85 

110.0 115.0 123.0 

13.9 15.2 11.1 

17.5 

3,0 

28.4 

88.6 

0.457 

307.5 

1.42 

°F 

in. H=0 

grams 

grams 

ppm 

ppm 

(in. Hz0) 112 

F 

17.0 

4,0 

20.4 

90.2 

0.493 

303.0 

0.78 

CO= 

SO2 

CO 

(sqrt Z•P)•va 

t• 

HCL mg 

28.87 

-0.23 

0.84 

0.986 

1.800 

0.375 

55.579 

76.9 

2.79 

116.0 

13.4 

16.0 16.8 

4.0 3.7 

31.1 

92.6 

0.484 

306.7 

0.81 

26.64 

90.48 

0.478 

305.7 

1.00 
16-D Commerce Ave. Hueytown• Alabama 

Cflont: Boral Brick Job No.: 27109 

Source: DIFF Bat/house Stack Data Input By: Art Otero 

Description Formulas S•/mbol Units Ca•c,l=h=•i Data 

Run Number 

Test Date 

Time Began-Ended 

1. Stack Pressure 

2. Meter Pressure 

3. Standard Meter Volume 17.64" Y= (vmrl'•)" (Pa,• tJt 113.6] V,•,• 

4a. Standard Volume of Water Vapor Condensed :0.04706"Ww 

4b. Standard Volume of Water Collected in Silica Gel 

5. Moisture Fraction 

9. Molecular Weight Of Stack Gas, dry basis 

10. Molecular Weight Of Stack Gas, wet basis 

11. Average Stack Gas Velocity 85.49•;p'(sqrt ,•P)=,•'SQRT((T,) (P,*Mw|)j 

in. Hg 

dscf 

scf 

scf 

g/g-mole 

g/g-mole 

ft/s 

3 AVERAGE 

03114/07 03/14107 03/14/07 

1126-1232 1300-1404 1414-1517 

28.85 28.86 28.85 28.85 

29.06 29.09 29.08 29.08 

50.033 53.909 53.089 52.344 

5.177 5.412 5.788 5.459 

0.655 0.717 0.523 0.632 

0.1044 0.1021 0.1063 0.1042 

29.180 29.320 29.280 29.260 

28.013 28.164 28.081 28.086 

31.98 34.28 33.82 33.362 

12. Stack Gas Flow @ Stack Conditions 60"%',• •, ac• 30,518 32,715 32,274 31,836 

13. Stack Gas Flow @ Standard Cunditions Q,'(T,•,,K,}-(PJP=•] Q, scrm 20,238 21,824 21,425 21,162 

14. Stack Gas Flow @ Dry Standard Conditions Q,'(1-B•)*(T•#T=J*(P=/P=•) o• 18 125 19 597 19 148 18 957 

14b. Hydrogen Chlodde concentration @ Std.Cond..Grains/Cu.FL =(0.01543-HCI.•)IQ• HCLcs grldscf 4.379E-04 2.233E-04 2.354E-04 2.989E-04 

15b. Hydrogen Chlodde emissions, Ibs per hour =(60/7000)°HCLQ•e°Q=d HCl -Ib•hr Ibs/hr 0.07 0.04 0.04 0.05 

16 Sulfur Dmxide (S02) Gas Concentration =c •==° MW1385 10 • Ibs/dscf 4.73E-06 3.39E-06 5.17E-06 4.43E-06 

t16. Carbon Monoxide (CO) Gas Concentration ---c•,• MW 1385.1 10 C• Ibs/dscf 6.45E-06 6.56E-06 6.74E-06 6 58E-06 

12 Sulfur Dmx•de (SO•) Gas Concen•ation ---c•oz" Q=,•* SO SOz4b/hr Ib•r 5.14 3.99 5.94 5.02 

21. Carbon Monoxide (CO) Gas Concentration =Coo O,•* 62:• CO-•b•hr Ib/hr 7.01 7.71 7.74 7.49 

122. Volume collected through nozzle =TJPs'[O.00266S"V•¢+ v,'Y,P,rr=] v, acf 84.243 89.998 89.484 87.9O8 

24. Isokinetic Sampling Rate, Percent 100"Vn/(S0°v=OA,,*e) % 95.40 95.07 95.82 95.43 

% Diffare•ce, (Callbfatiot• must be within § • Of original Y-i•actor) •::::•::•::•::•::•::i•::::::::::•i•::•::•::•::::::•:::•::::::•::•::::::::::•i•i::•::•::•::::•::•i•::•::::::::•:•:•::::::•::::::::•::•::•::•::•::•::•::•::::; .4.16% 

Procedures 

The emission rates were determined using EPA Methods 1-4, 6C, 10 and 26A of CFR 

Title 40, Part 60, Appendix A. The calibration and quality assurance procedures of EPA 

CFR 40 Part 60 Appendix A for all methods, and the "Quality Assurance Handbook for 

Air Pollution Measurement System" Volume III Stationary Source-Specific Methods 

were followed throughout the duration of the field and laboratory testing. 

The most current revision revised for each method (as described in the Federal 

Register) was used. 

Stack Gas Volumetric Flow 

The velocity of the gas stream was determined according to EPA Reference Method 1 

and 2 by reading the instantaneous velocity head with an inclined manometer at each 

sampling point with a calibrated S-type pitot tube attached adjacent to the sample 

nozzle. The stack pressure was measured with the static side of an S-type pitot tube. 

A calibrated pyrometer was used to measure stack temperature at each sampling point. 

Moisture Content 

The moisture content used for calculating the gas stream flow rate was determined by 

weighing the amount of condensed moisture collected in the impingers of the sampling 

train as described in EPA Reference Method 4. 

The moisture collection system consists of a series of impingers. Ice is placed around 

the•mpingers. The outlet temperature of the impingers is•monitored and recorded 

throughout the duration of the testing to verify the temperature is below <68 o 

Sulfur Dioxide Method 6C 

A Western Research Model 721M SO2 (Method 6C) analyzer provided continuous 

analysis of SO2 in the gas stream. The basic analytical principle involves quantitative 

measurement of the absorption of UV radiation by SO2 molecules. The analyzer uses a 

single light source, which emits an appropriate wavelength, illuminating the sample cell 

through which the sample is continuously passed. Narrow-band optical filters are 

rotated through the beam, and the radiation passed through the optical filters and 

sample cell is detected by a single photo-detector. The signal pulses from the photo- 
detector are separated by a multiplexor into a measuring channel and a reference 

channel. A log ratio amplifier computes the logarithm of the input signal ration, 

producing a signal that is proportional to the SO2 concentration. The dual-range 

analyzer has a digital readout, as well as 0-10.0 V DC output terminals. The full scale of 

the instrument was set at 221 ppm. 

Carbon Monoxide Method 10 

The CO emissions w•re measured using a Siemens Ultramat 23 analyzer. This monitor 

is a selective non-dispersive infrared radiation (NDIR) gas analyzer that operates on the 

infrared double-beam alternating light principle. The full range for the CO component of 

this instrument throughout the test period was 227 ppm. 

Sampling System 

Due to the new test requirements, a stratification test was determined. It was found 

that the gas stream was unstratified. A single point was used to collect the gas 

samples. Samples were extracted from the .gas stream by a heated stainless steel 

probe maintained at a set temperature of 250 degrees Fahrenheit, through a ten (10) 

foot heated sample line that was heated to a temperature between 225 and 250 

degrees, through a chilled sample conditioner to remove the moisture in the gas stream 

and transported to the test trailer through unheated teflon sample lines to the analyzers. 

Data Acquisition 

Concentration values were collected using a STRATA data acquisition system. The 

data wamrecorded every fifteen-seconds and•hen averaged for each sixty-second 

interval. Each minute average was then averaged for the duration of each test run. 

During all testing, the unit was operating within normal operating parameters; at a range 

appropriate in accordance with applicable permits. 

Hydrogen Chloride Method 26A (HCI) 

Preliminary data was used to determine stack temperature, pressure, and range of 

velocity heads, moisture content and stack gas dry molecular weight prior to sampling. 

The meter box was leak checked from the pump to the orifice. Initial and final leak 

checks of the sampling system and pitot lines were performed as outlined in Method 5 

and were recorded on the data sheets. The nozzle (glass with an angle of taper of 30 
degrees and of button hook design) was calibrated before and after the test using a 

micrometer and was recorded on the field data sheets. 

The sampling probe was placed at each sampling point to provide a total sampling time 

of sixty (60) minutes. The gases were drawn through a glass nozzle attached to a 

heated glass lined probe. The probe was maintained at the proper settings to obtain 

an exit temperature of greater than 248 o F during sampling. The gases then proceeded 

through borosilicate glass filter holder, with a Teflon frit filter support through a Teflon 

filter to remove particulate matter. The filter was maintained at a temperature of greater 

than 248 0 F. These temperatures were recorded at each point on the field data sheets. 

The gases were then scrubbed through a series of four pre-weighed impingers to 

capture hydrogen halides and halogens and moisture. (The optional first impinger for a 

knockout for moisture was not used.) The first and second impingers contained 

approximately 100 ml of a 0.1N H2SO4 (acid) solution and the third and fourth impingers 

contained approximately 100 ml of a 0.1 N NaOH (alkaline) solution. The fifth impinger 

contained pre weighed silica gel to remove any remaining moisture. The gases pass 

through the impinger series in an ice bath to maintain a maximum exit temperature of 

68 o F. This temperature was also recorded on the data sheets. The clean and cool 

gases then entered the meter box where the gas flow and temperature were measured. 

After the completion of the test the sampling train and the probe nozzle assembly was 

transferred to the cleanup area making sure no particulate was lost. The cleanup data 

was recorded. 

The first and second impinger contents were transferred to its tared container, weighed 

and the rinsing from the glassware were added to this container. The third and fourth 

impinger was transferred to its respective tared container, weighed and the rinsing from 

the glassware was added to this container. The silica gel from the fifth impinger was 

transferred to its respective tared container and weighed. A blank of the sulfuric acid 

solution, sodium hydroxide, distilled water and acetone was taken. These containers 

were clearly marked and transported to the laboratory for analysis. 
Entec Services, Inc 

•i•i•ii!•i•:i•:• .................................................................. 

STACK DRAWING & TRAVERSE POINT LOCATION 

Client: Boral Brick 

Job No. 27109 Source: DIFF Baghouse Stack 

Input By: Art Otero 

Type of Traverse: Velocity (V) or Particulate (p): 

Stack Diameter, inches: 54 

Stack Height, feet: 75 

•erties: Inches 

Upstream Disturbance: 222.0 

Downstream Disturbance: 387.0 

P Port Type Nipple Port Diameter 

Stack Area, Ft•: 

Number of Ports: 

Duct Diameters Length of Port, inches: 

4.11 Total Number of Traverse Points: 

Number of Poin•_.•per diameter: 

7.17 

15.904 

2 

6.00 

12 

6 

54.0' INCHES 

222.0 INCHES 

Inside Stack Outside Nipple Point N(• Inches Inches 

1 2.4 8.4 

2 7.9 13.9 

3 16.0 22.0 

4 38.0 44.0 

5 46.1 52,1 

6 51.6 57.6 

Adjusted points diameter > 24" no point closer than 1.0 inch Adjusted points diameter_< 24" no point closer than 0.5 inch 

Stack Diameters between 12-24 inches minimum points are 8 4 points per port if the 8 12 diameters downstream and 

upstream criteria is met. 

387.0 
Method 26A Sampling Train 

Filter Exit Temperature 

(>248 F) 

rip!rig npmg 

#2 

I.OOml 

0.Ibl 0AN 

LSO •aOH •sil 

lmpingerExit Temperature 

(<68 F) 

Exhaugt ®O0®O0 

J Temp. and Flow 

Controllers 

i0 g 

• Ice-Ba•h 

12 
Instrument Sampling Train 

In-s•ack 

Filter 

Cali_b•tiO..n Gas Line 

Three WaY valve • 

t .H•a•e• | fH•a•dTeflonLine I •!•.•..• / • 

•Steel probe; • 

Moisture • 

Sy• 

comrnunicafon Lines 

Acquisition 

[ System 

Flow. Control 

.Panet. 

i 

0 (:::) 

SO2 

CO 

Calibration 

GaSes. 

13 
Field Dat• S •eets 
15 ̧ 
ENTEC Services, Inc. 

16-D Commerce Ave. Hueytown, Alabama 35023 

Client: Boral Brick Test Date: 3114/2007 

Source: DIFF Baghouse Stack Run Number: 1 

HYDROGEN CHLORIDE FII•U3 DATA, EPA METHOD 26A 

1-1 0.28 

1-2 0.30 

1-3 0.25 

1-4 0.12 

1-5 0.18 

1-6 0.21 

2-1 0,14 

2-2 0.17 

2-3 0.22 

0.5292 3.36 

K-Factor 

0.5477 3.60 

0.5000 3.00 

0.3464 1.44 

O.4243 2,16 

0.4583 2.52 

0.3742 1.68 

0.4123 2.04 

311 71 

311 70 

309 70 

305 70 

305 69 

308 74 

304 73 

301 73 

0.4690 2.64 309 71 

2-4 0.31 0.5568 3.72 308 70 

2-5 0.27 0,5196 3.24 309 72 

2-6 0.12 0.3464 1.44 310 75 

12.00 0.21 0.4570 2.57 307.5 71.5 
0 

.£3 

•EEE 

" 
Operator: 

Plant Name: 

Location: 

Lynn Beane 

Boral Brick 

Union City, OK 

Boral Brick 

Union City DIFF Oultet (Stack) 

Test Run No. 1 

Date Time CO; ppm SO2; ppm 

3/14/2007 11:30:12 71.4 

3/14/2007 11:31:11 70.2 

3114/2007 11:32:11 69.0 

3114/2007 11:33:12 68.1 

3/14/2007 11:34:12 67.5 

3/14/2007 11:35:11 67.1 

3/14/2007 11:36:11 66.6 

3114/2007 11:37:12 66.3 

3/14/2007 11:39:11 74.1 

3/14/2007 11:40:12 92.2 

3/14/2007 11:41:12 95.8 

3/14/2007 11:42:13 110.0 

3114/2007 11:43:12 116.9 

3/14/2007 11:44:12 117.5 

3114/2007 11:45:11 131.8 

3/14/2007 11:46:11 149.2 

3114/2007 11:47:12 125.9 

3114/2007 11:48:12 93.0 

3114/2007 11:49:13 77,9 

3/14/2007 11:50:12 72.9 

3/14/2007 11:51:12 72.1 

3/14/2007 11:52:13 71.4 

3114/2007 11:53:13 70.2 

3/14/2007 11:54:12 69.0 

3/14/2007 11:55:12 67.5 

3/14/2007 11:56:11 66.6 

3/14/2007 11:57:12 65.8 

3/14/2007 11:58:12 65.1 

3/14/2007 11:59:11 64.9 

3/1412007 12:00:11 65.3 

3/14/2007 12:01:10 66.6 

3114/2007 12:02:10 84.7 

3/14/2007 12:03:09 97.8 

3114/2007 12:04:09 109.7 

3114/2007 12:05:10 119.4 

3/14/2007 12:06:11 122.3 

3/14/2007 12:07:11 141.6 

3/14/2007 12:08:10 141.4 

311412007 12:09:10 171.3 

3/14/2007 12:10:11 152.2 

3114/2007 12:11:09 114.2 

3/14/2007 12:12:10 97.5 

3/14/2007 12:13:11 83.7 

3/14/2007 12:14:11 76.1 

3/14/2007 12:15:12 74.9 

3/14/2007 12:16:13 66.3 

311412007 12:17:13 61.7 

3/14/2007 12:18:12 63.5 

311412007 12:19:12 63.7 

3/14/2007 12:20:11 64.1 

3/14/2007 12:21:11 64.2 

3/14/2007 12:22:12 64.2 

3/1412007 12:23:13 64.1 

3114/2007 12:24:13 63.9 

3114/2007 12:25:12 79.0 

3/14/2007 12:26:12 98.6 

3/14/2007 12:27:11 109.2 

3/14/2007 12:28:11 119.3 

3114/2007 12:29:12 123.4 

3/14/2007 12:30:10 124.9 

Test Run End 88.8 

10.3 

9°0 

8.7 

8.5 

8.8 

9.0 

8.3 

7.6 

6.0 

4.7 

6.8 

39.9 

87.6 

137.9 

219.0 

84.2 

37.5 

25.4 

20.1 

16.7 

14.4 

13.1 

12.0 

11.1 

10.7 

10.3 

9.5 

8.8 

8.7 

9.0 

9.1 

7.3 

5.7 

8.5 

45.2 

93,2 

140.9 

161.0 

83.2 

39.1 

24.9 

17.9 

13.6 

11.4 

10.4 

9.2 

8.0 

7.4 

7.3 

7.1 

7.4 

7.4 

7.4 

6.7 

5,6 

4.9 

5.4 

34.9 

82.8 

139.9 

29.7 
Calculation of Average Emissions 

Test Performed For: 

Boral Brick 

Union City, Oklahoma 

Kiln DIFF Exhuast 

Compliance 

Date:3/14/07 

Test Performed By: 

Entec Services, Inc. 

Birmingham Division 

Test Trailer 901 

Mr. Lynn Beane 

Run 1 

Calibration Gas Value 

0.0 ppm CO 

227.00 ppm CO 

Initial Calibration 

0.0 ppm 

228.2 ppm 

Final Calibration 

0.1 ppm 

226.5 ppm 

Average 

0.05 

227.35 

0.0 ppm SO2 

221.00 ppm SO2 

0.0 ppm 

221.0 ppm 

3.0 ppm 

221.0 ppm 

1.50 

221.00 

Mean Reference Values: 

88.8 ppm CO 

29.7 ppm SO2 

Corrected Results: 

88.64 ppm CO 

28.42 ppm SO• 

Basis: 

DRY 

DRY 

19 

ENTEC Services, Inc. 

16-D Commerce Ave. Hueytown, Alabama 35023 

Client: Boral Brick Test Date: 3/14/2007 

Source: DIFF Baghouse Stack Run Number: 2 

HYDROGEN CHLORIDE FIELD DATA, EPA METHOD 26A 

Traverse Point DeltaP Sq. Rt. DeltaP DeltaH Stack Temp. (°F) Meter Temp.(OF) 

1-1 

1-2 

1-3 

0.28 0.5292 

0.32 0.5657 

0.20 0.4472 

1-4 O.23 0.4796 

1-5 0.23 0.4796 

1-6 

2-1 

2-2 

2-3 

2-4 

K-Factor 

0.25 0.5000 

0.29 0.5385 

0.23 0.4796 

0.26 

0.22 

0.5099 

0.4690 

3.39 

3.87 

2.42 

302 

301 

298 

75 

73 

75 

2.78 296 76 

2.78 303 79 

3.02 307 

304 

305 

3O4 

307 

3.51 

2.78 

3.14 

2.66 

2-5 0.18 0.4243 2.18 305 

2-6 0.24 0.4899 2.90 304 

0.4927 2.95 303.0 

8O 

8O 

8O 

79 

79 

8O 

82 

78.2 

21 
138 
Operator:, 

Plant Name: 

Location: 

Lynn Beane 

Boral Brick 

Union City, OK 

Boral Brick 

Union City DIFF Oultet (Stack) 

Test Run No. 2 

Date Time CO; ppm $02; ppm 

3114/2007 12:51:49 123.5 

3114/2007 12:52:49 124.2 

3/1412007 12:53:49 136.7 

3/14/2007 12:54:50 143.0 

3114/2007 12:55:50 124,6 

3114/2007 12:56:49 97.4 

3/14/2007 12:57:49 88.2 

3114/2007 12:58:50 73.3 

3/14/2007 12:59:49 71.2 

3114/2007 13:00:49 70.6 

3114/2007 13:01:50 69.6 

3114/2007 13:02:50 68.5 

3114/2007 13:03:49 67,2 

3/14/2007 13:04:49 66.2 

3/14/2007 13:05:50 65.4 

3/14/2007 13:06:51 64.8 

311412007 13:07:51 64.5 

3114/2007 13:08:50 64. 8 

3114/2007 13:09:50 66.1 

3/14/2007 13:10:49 84,4 

3/14/2007 13:11:50 97.4 

3/14/2007 13:12:50 109.4 

3/14/2007 13:13:51 118.1 

3114/2007 13:14:51 119.0 

3/14/2007 13•15:50 137.9 

311412007 13:16:50 141.6 

3/14/2007 13:17:51 173.3 

3/14/2007 13:18:50 141.3 

3114/2007 13:19:50 103.6 

3114/2007 ,13:20:51 93.8 

3/14/2007 13:21:51 80,0 

3114/2007 13:22:50 75,3 

3114/2007 13:23:50 63.5 

3114/2007 13:24:51 62.1 

3/14/2007 13:25:51 61.7 

3/14/2007 13:26:51 62.1 

3/14/2007 13:27:50 62.6 

3/14/2007 13:28:50 63,5 

3114/2007 13:29:51 64,2 

3114/2007 13:30:52 64.4 

3114/2007 13:31:52 64.5 

3114/2007 13:32:51 64.3 

3/14/•nn7 3:33:51 82.6 

3/14/2007 13:34:50 102.6 

3/14/2007 13:35:50 114.6 

3/14/2007 13: 36:51 123.4 

3/14/2007 13:37:52 125.4 

3114/2007 13:38:52 126.7 

311412007 13:39:51 141.0 

3114/2007 13:40:51 132.7 

3114/2007 13:41:50 111.8 

3114/2007 13:42:50 89.8 

3/14/2007 13:43:51 77.5 

3114/2007 13:44:50 72.3 

3/14/2007 13:45:50 71.7 

3/14/2007 13:46:51 71.3 

3/14/2007 13:47:51 70.5 

3/14/2007 13:48:50 69.7 

3/14/2007 13:49:50 68,9 

3/14/2007 13:50:51 68.2 

3/14/2007 13:51:50 67.7 

Test Rmt End 90.6 

78.4 

136.4 

217.6 

64.7 

26.6 

12.8 

5.4 

0.7 

-1.1 

-2.3 

-3,3 

-6.0 

-6,4 

-7,9 

-6.6 

-9.5 

-10,0 

0.3 

8.3 

6,6 

5,2 

6,7 

33.6 

80.5 

124,0 

138.7 

64.3 

30.7 

17.8 

12.5 

10.2 

7.8 

6.2 

4.4 

3.3 

2.6 

2.1 

2.1 

2.2 

1.9 

2.1 

2.2 

1.7 

1.6 

1.7 

5.8 

32.6 

83.1 

105.0 

35.0 

19.9 

12.7 

11,4 

10.7 

10.2 

9.6 

9.8 

9.5 

9.4 

9,3 

9.2 

23.2 
Calculation of Average Emissions 

Test Performed For: 

Boral Brick 

Union City, Oklahoma 

Kiln DIFF Exhuast 

Compliance 

Date:3/14/07 

Test Performed By: 

Entec Services, Inc. 

Birmingham Division 

Test Trailer 901 

Mr. Lynn Beane 

Run 2 

Calibration Gas Value 

0.0 ppm CO 

227.00 ppm CO 

Initial Calibration 

0.1 ppm 

226.5 ppm 

Final Calibration 

-0.1 ppm 

229.1 ppm 

Average 

0.00 

227.80 

0.0 ppm S02 

221.00 ppm S02 

3.0 ppm 

221.0 ppm 

3.0 ppm 

222.0 ppm 

3.00 

221.50 

Mean Reference Values: 

90.5 ppm CO 

23.2 ppm SO2 

Corrected Results: 

90.2 ppm CO 

20.4 ppm SO2 

Basis: 

DRY 

DRY 

ENTEC Services, Inc. 

16-D Commerce Ave. Hueytown, Alabama 35023 

Client• Boral Brick Test Date: 3114/2007 

Source: DIFF Baghouse Stack Run Number: 3 

HYDROGEN CHLORIDE FIELD DATA, EPA METHOD 26A 

Traverse Point Delta P 

1-1 0,30 

1-2 0.26 0.5099 

1-3 0.20 0.4472 

1-4 

1-5 

1-6 

2-1 

0.23 

0.24 

0.19 

0.24 

2-2 0.27 

2-3 0.27 

2-4 

2-5 

2-6 

0.25 

0.21 

0.17 

Sq. RLDeltaP 

0.5477 

0.4796 

Delta H 

3.63 

3.14 

2.42 

2.78 

Stack Temp. (°F) 

301 

301 78 

303 78 

306 

0.4899 2.90 310 

0.4359 2.30 312 

0.4899 2.90 306 

0.5196 3.26 310 

0.5196 

0.5000 

0.4583 

3.26 

3.02 

0.4123 2.06 

2.85 

K-Factor 

12.09 0,24 0.4842 

3O9 

310 

304 

308 

306.7 

Meter Temp. (°F) 

81 

79 

79 

81 

80 

80 

83 

83 

85 

80.9 

26 
27 
Operator. 

Plant Name: 

Location: 

Lynn Beane 

BoralBdck 

Union Ci•, OK 

Boral Brick 

Union City DIFF Oultet (Stack) 

Test Run No. 3 

Date Time CO; ppm SO2; ppm 

311412007 14:10:01 74.9 14.2 

3/14/2007 14:11:01 72.7 12.1 

3/14/2007 14:12:02 70.9 10.7 

311412007 14:13:02 69.8 14.8 

3/14/2007 14:14:01 69.0 12.8 

3/14/2007 14:15:01 68.3 11.4 

3/14/2007 14:16:02 68.1 10.5 

3/14/2007 14:17:02 68,9 9.1 

3/14/2007 14:18:01 88.0 8.9 

3114/2007 14:19:02 99.4 7.5 

3/14/2007 14:20:02 120.7 6.5 

3/14/2007 14:21:01 126.6 6.1 

3114/2007 14:22:01 140.6 33.4 

311412007 14:23:02 146.7 92.1 

3/14/2007 14:24:02 147.4 145.2 

3114/2007 14:25:01 154.8 155.0 

3114/2007 14:26:02 171.1 106.5 

311412007 14:27:02 173.2 46.9 

3114/2007 14:28:01 121.2 28.9 

3/14/2007 14:29:01 100.1 20,2 

3114/2007 14:30:02 65.1 17.2 

3114/2007 14:31:02 80.7 14.5 

3114/2007 14:32:01 71.0 12.9 

3114/2007 14:33:02 68.3 12.0 

3/1412007 14:34:02 67.4 10.4 

3114/2007 14:35:01 66.2 10.0 

3114/2007 14:36:01 65.3 9.8 

3114/2007 14:37:02 64,5 9,9 

3/14/2007 14:38:03 64.9 10.4 

3/14/2007 14:39:03 65.4 11.0 

3/14/2007 14:40:02 65.5 10,9 

3/14/2007 14:41:02 65.7 10.8 

3114/2007 14:42:03 76,1 10.0 

3114/2007 14:43:03 102.2 9.4 

311412007 14:44:02 115.1 10.5 

3/14/2007 14:45:03 127.5 40.2 

3/14/2007 14:46:03 131.5 97.4 

3/14/2007 14:47:02 133.2 148.4 

3/14/2007 14:48:02 148.5 240.8 

3/14/2007 14:49:03 147.3 82,5 

311412007 14:50:03 129.5 42.0 

3/14/2007 t4:51:02 101.2 29.1 

3114/2007 14:52:03 83.4 23.7 

3114/2007 14:53:03 75.8 20.9 

3/1412007 14:54:02 74.6 19.3 

3/14/2007 14:55:02 73.9 17.7 

3/1412007 14:56:03 73.1 16.7 

3/14/2007 14:57:01 71.9 16.4 

311412007 14:58:02 70.7 16.0 

3/14/2007 14:59:01 70.0 16.0 

3/14/2007 15:00:01 69.4 16.7 

3114/2007 15:01:02 69.0 15.5 

3114/2007 16:02:02 68.7 15.2 

3/14/2007 15:03:01 68.6 14.8 

3/14/2007 15:04:01 68.6 14,5 

3/14/2007 15:05:02 79.2 13.3 

3114/2007 15:06:01 97.1 12,8 

3/14/2007 15:07:01 99.9 13.0 

3/14/2007 15:08:02 115.9 43.0 

311412007 15:09:02 119.1 89.5 

3/14/2007 15:10:01 120.0 137.2 

Test Run 3 End 94.4 33.9 

28 
Calculation of Average Emissions 

Test Performed For: 

Boral Brick 

Union City, Oklahoma 

Kiln DIFF Exhuast 

Compliance 

Date:3/14/07 

Calibration Gas Value 

0.0 ppm CO 

227.00 ppm CO 

0.0 ppm SO2 

221.00 ppm S02 

Initial Calibration 

-0.1 ppm 

229.1 ppm 

3.0 ppm 

222.0 ppm 

Test Performed By: 

Entec Services, Inc. 

Birmingham Division 

Test Trailer 901 

Mr. Lynn Beane 

Run 3 

Final Calibration 

3.4 ppm 

228.6 ppm 

Average 

1.65 

228.85 

3.0 ppm 

223.0 ppm 

3.00 

222.50 

Mean Reference Values: 

94.4 ppm CO 

33.9 ppm SO2 

Corrected Results: 

92.6 ppm CO 

31.1 ppm SO2 

Basis: 

DRY 

DRY 

29 
Control Room Production Data 
Production Data 

The information on the following pages was received by email from Mr. Frank Porter of 

Boral Bricks for the testing performed at their facility in Union City, Oklahoma, on March 

14, 2007. 

31 
Sent: Thursday, March 29, 2007 10:26 AM 

To: James Brewer (Bricks Union City); Justin McKenna (Bricks Muskogee) 

Subject: Fw: Control Room Data Union City 

Importance: High 

Please verify the production data for the stack testing. 

I am planning to have feedback on the turnaround document this afternoon. Sorry for the delay. 

Thanks, 

Frank 

Original Message 

From: Lynn Beane <LBeane@entecservices.com> 

To: Frank Porter (Bricks Phenix City) 

Cc: tomlotzsr@entecservices.com <tomlotzsr@entecservices.com> 

Sent: Thu Mar29 10:21:53 2007 

Subject: Control Room Data Union City 

Frank, 

Just to verify the lab production data for Union City. 

18.14 tons fired brick 

36 tons of lime injection 

D. Lynn Beane 

Entec Services, Inc. 

Operations Manager 

1-800-429-8445 

1-205-491-6676 (o) 

1-205-613-5473 (c) 

www.entecservices.com <._h....•...;_./../__w_•,..e_n._t_.e._.c...s..e.. _ry_.i._c_._e..s_..c..o....m..> 

4/11/2007 

32 
Orig inal Test Protocol 
Entec Services, 

16-D Commerce Avenue 

Hueytown, Alabama 35023 

Telephone: (205) 491-6676 

Fax: (205) 491-6614 

Test Protocol for the 

Kiln DIFF Stack 

Compliance Emissions Testing at the 

Boral Brick Company Facility 

Located in 

Union City, Oklahoma 

Submitted to: 

Borai_.Brick 

P. O. Box 1178 

Columbus, Georgia 31902 

Attention: Mr. Frank Porter 

cc: State of Oklahoma Department of Environmental Quality Mr. Johnnie Little 

Entec Project No.27109 

Completed By: 

Protocol Submitted: December 18, 2006 

Reviewed By: 

Tom Lotz 

QA / QC Manager 

34 
Test Prog ram 

This proposed test program will take one day to complete. Entec proposes to begin 

testing on the week of February 19, 2007. Entec will arrive on site and begin testing on 

the DIFF stack at approximately 9:00 am for Hydrogen Chloride, Sulfur Dioxide & 

Carbon Monoxide emissions. The following are the test procedures, QA/QC 

procedures, and other documentation to be used for this test program. 

All production data will be provided by Boral Brick and be included in the final report. 

Procedures 

The Hydrogen Chloride, Sulfur Dioxide, and Carbon Monoxide on the Brick Kiln DIFF 

outlet will be determined by EPA Methods 1-4, 6C, 10 and 26A of the CFR Title 40, Part 

60 Appendix A. The calibration and quality assurance procedures of EPA CFR 40 Part 

60 Appendix A Methods 1-4, 6C, 10 and 26A of the "Quality Assurance Handbook for 

Air Pollution Measurement System" Volume III Stationary Source-Specific Methods will 

be followed throughout the duration of the field and laboratory testing. The most current 

CFR revision of each method (July 1, 2004) will be used. The following paragraphs 

summarize the protocol. 

Stack Gas Volumetric Flow 

The velocity of the gas stream will be determined according to EPA Reference Method 

2 by reading the instantaneous velocity head with an inclined manometer at each 

sampling point with_a•alibrated S-type pitot tube•attached adjacent•o•he sampte 

nozzle. The stack pressure will be measured with the static side of an S-type pitot tube. 

A calibrated pyrometer will be used to measure stack temperature at each sampling 

point. The stack will be tested for cyclonic flow according to EPA Reference Method 2. 

Stack Gas Molecular Weight 

The carbon dioxide and oxygen concentrations will be determined using EPA Reference 

Method 3. A grab sample of the flue gas will be extracted from the gas stream during 

each particulate test run and analyzed using a Fyrite analyzer. The molecular weight of 

the gas will be calculated based on the moisture, oxygen and carbon dioxide content 

3• 
along with the measured stack gas temperature. The Fyrite sampling system will be 

verified to be leak free prior to the analysis. 

Moisture Content 

The moisture content used for calculating the gas stream flow rate is determined by 

measuring the amount of condensed moisture in the series of impingers in the sampling 

train as described in EPA Reference Method 4 (in conjunction with Method 26A 

impinger setup) at the completion of each test. 

The moisture collection system consists of a series of impingers. Ice is placed around 

the impingers to maintain a temperature <68 o F. The outlet temperature of the impingers 

is monitored and recorded throughout the duration of the testing to verify the 

temperature is below <68 o F. 

Hvdroaen Chloride 

Preliminary data will be used to determine stack temperature, pressure, and range of 

velocity heads, moisture content and stack gas dry molecular weight prior to sampling. 

The meter box will be leak checked from the pump to the orifice. Initial and final leak 

checks of the sampling system and pitot lines will be performed and will be recorded on 

the data sheets. The nozzle (glass with an angle of taper of 30 degrees and of button 

hook design) will be calibrated before and after the test using a micrometer and will be 

also recorded on the data sheets. 

The sampling probe will be placed at each sampling point to provide a total sampling 

time of at least 60 minutes and a volume of at least 31.8 cubic feet. The gases will be 

drawn through a glass nozzle attached to a heated glass lined probe. The probe will be 

maintained at the proper setting to obtain an exit temperature of > 248 0 F. The gases 

then proceeded through borosilicate glass filter holder, with a Teflon frit filter support 

through a tarred teflon or quartz fiber filter to remove particulate matter. The exit of the 

filter will be maintained at a temperature of > 248 o F. These temperatures will be 

recorded at each point on the data sheets. 

The gases will be then scrubbed through a series of four impingers to capture hydrogen 

halides and halogens and moisture. The optional first impinger for a knockout for 

3 

35 
moisture will be used.) The second and third impingers will contain approximately 100 

ml of a 0.1N H2SO4 solution and the fourth and fifth impingers will contain approximately 

100 ml of a 0.1 N NaOH solution. The sixth impinger will contain pre weighed silica gel 

to remove any remaining moisture. The gases pass through the impinger series in an 

ice bath to maintain a maximum exit temperature of 68 0 F. This temperature will be 

also recorded on the data sheets. The clean and cool gases then entered the meter 

box where the gas flow and temperature .will be measured. 

After the completion of the test leak rate determinations will be made. Then the sampling train and the probe nozzle assembly will be transferred to the cleanup area making 

sure no sample is lost. The cleanup data will be recorded. 

Each acetone rinse from the nozzle, and probe, will be combined and placed in a sealed 

container. For the group of tests an acetone blank of approximately 200 milliliters will 

be placed in a sealed container. The first, second and third impinger contents will be 

transferred to its tarred container, weighed and the rinsing from the glassware will be 

added to this container. The fourth and fifth impinger contents will be transferred to its 

respective tarred container, weighed and the rinsing from the glassware will be added to 

this container. The silica gel from the fifth impinger will be transferred to its respective 

tarred container and weighed. A blank of the sulfuric acid solution, sodium hydroxide, 

distilled water and acetone will be taken. These containers will be clearly marked and 

transported to the laboratory for analysis. 

4 

37 
QA / QC Procedu res 

Specific quality assurance / quality control procedures will be adhered to during this test 

project to provide valid and scientifically defensible data. For any environmental field 

and laboratory measurement, a degree of uncertainty exists in the data due to inherent 

limitations of the measurement systems employed. The objective of a QA/QC program 

is to produce data of known precision, accuracy, representation, completeness and 

comparability. The objective in this test project is to determine compliance with 

applicable air permit requirements. The final data user in this project will be the State of 

Oklahoma Department of Environmental Quality. 

The following section details all QC procedures to be followed during the manual 

sampling activities. 

Velocity / Volumetric Flow Rat•- 

Volumetric flow rates will be determined during each isokinetic test run. The following 

QC steps will be adhered to during these tests: 

Reported duct dimensions will be checked by physical measurements to determine 

cross-sectional duct area. 

Pitot tube coefficients are determined based on physical measurement techniques 

as delineated in Method 2 before and after each test. 

The Type-S pitot tube are visually inspected before and after sampling. 

The pitot tube is installed on the sampling probe with the proper orientation and 

spacing from the sampling nozzle. 

Before each series of tests, thermocouple readings for the silica gel impinger exit 

temperature are checked against an N.I.S.T. traceable thermometer. 

The oil manometer is leveled and zeroed before each test run. 

Both legs of the pitot tube are leak-checked before and after sampling. 

Proper orientation of the pitot tube is maintained while making measurements. The 

roll and pitch axis of the pitot tube is maintained at 90 o to the flow. 

An average velocity pressure reading is recorded at each point instead ofrecording 

extreme high or low values. 

The pitot/manometer umbilical lines are inspected before and after sampling for 

moisture condensate. Lines are cleared if moisture is found. 

5 

38 
Molecular Weiqht Determination Fyrite Analysis 

The carbon dioxide and oxygen concentrations are determined using EPA Reference 

Method 3. A sample of the flue gas is extracted from the gas stream during each test. 

The samples are analyzed with a Fyrite gas analyzer. The following QC steps are 

adhered to during these tests: 

The sampling train is leak checked before and after each sample is taken. 

The samples are run in triplicate for accuracy. 

Standardization is performed to audit the reagents and the operators technique. A 

known mixture of CO2 and O2 is analyzed and repeated with 3 consecutive values 

+/- 0.5 percent of the known value. 

Two NIST traceable gas cylinders are run against the instrument to audit the 

accuracy of the analyzer and the analyzer operator technique. One cylinder 

contains 2 to 4 percent O2 and 14 to 18 percent CO2. The second cylinder contains 

2 to 4 percent CO2 and about 15 percent 02. 

Moisture Determination 

Stack gas moisture content (Bws) is determined by dividing the mass of moisture 

collected by the impingers or stainless steel condenser and silica gel impinger by the 

standardized volume of gas sampled. The following QC steps are adhered to during 

these tests: 

The indicating silica gel is fresh for the first run and periodically inspected and 

replaced during runs, if needed. 

The analytical balance is placed in a clean, motionless environment for weighing. 

]-he balance =s leveled and zeroed if necessary before each weighing. 

Preliminary silica gel impinger tare weights and post-run weights are weighed to the 

nearest 0.1 g. 

Before each sedes of tests, thermocouple readings for the silica gel impinger exit 

temperature are checked against an N.I.S.T. traceable thermometer. 

The silica gel impinger gas temperature is maintained below 68°F and recorded at 

every traverse point. 

Each impinger is wiped of surface moisture before post-run weighing. 

The volume of liquid captured is measured using a graduated cylinder with 1- 

milliliter increments. 

6 

39 
Hvdroc•en Chloride Sampling (Modified Sample Train w/o Particulate) 

Accurate HCI concentrations are dependent on the sample collection system and the 

final impinger collection system for analytical analysis. QC procedures that are followed 

-so that representative Hydrogen Chloride data is collected by the sampling system 

were: 

Only clean, well-maintained sampling equipment is used. 

Sampling ports are inspected and cleaned prior to sampling. 

All equipment is calibrated according to EPA standards. The dry gas meter is fully 

calibrated within the past 12 months using a set of calibrated orifices. 

The sampling train components exposed to sample gas are constructed of glass, or 

Teflon. 

Accurate barometric pressure is recorded at least once per day. 

The dry gas meter thermocouples are compared to ambient temperature prior to the 

test run as a check on operation. 

Pretest and post-test leak-checks are completed (must be less than 0.02 cfm or 4% 

of the average sampling rate). 

Before each series of tests, thermocouple readings for meter temperature, filter 

hotbox, probe, and filter exit temperatures are checked against an N.I.S.T. traceable 

thermometer. 

Readings of the dry gas meter, meter orifice pressure (/•H), meter temperatures, 

filter hotbox temperatures, probe temperatures, and filter exit temperatures are 

taken at every traverse point. 

Probe and fiite•temperatu•es are monitored andmaintainecLgrater than-248 °F for 

the DIFF Stack. 

The filter exit temperature was maintained at grater than 248 °F for the DIFF Stack. 

The gas meter is read to the thousandth of a cubic foot for the initial and final 

readings. 

The sampling velocity through the nozzle is maintained within 10% of the stack gas 

velocity (isokinetic sampling rate at 100+10%). 

All nozzle/probe recovery items are pro-cleaned and kept in containers when not 

being used. 

Probe and nozzle recovery includes wiping the outer surface clean of dust before 
sample recovery. Sample recovery consists of multiple brushing of the inner 

surface and twisting/rotating the probe during recovery operations. Transfer of rinse 

acetone to the sample container is accomplished Without loss of liquid. Nozzle and 

probe brushes are rinsed after brushing inner surfaces. 

Liquid levels are marked on sample containers and sealed for shipment to the 

laboratory. 

Acetone rinse blanks are collected for laboratory analysis. 

Prior to the initial run a y-factor check is performed to ensure that the meter is 

operating according to the original calibration to within 3% of the original y-factor. 

For the post-test calibration the alternative Method 5 post-test calibration 

procedures are used (Emission Measurement Center Approved Alternative Method 

ALT-009). 
Quality Assurance / Quality Control 

Procedures 

z•2 
QA / QC Procedures 

Specific quality assurance / quality control procedures were adhered to during this test 

project to provide valid and scientifically defensible data. For any environmental field 

and laboratory measurement, a degree of uncertainty exists in the data due to inherent 

limitations of the measurement systems employed. The objective of a QA/QC program 

is to produce data of known precision, accuracy, representation, completeness and 

comparability. The objective in this test project was to determine compliance with 

applicable air permit requirements. The final data user in this project will be the 

Oklahoma Department of Environmental Quality (DEQ). 

The following section details all QC procedures followed during the manual sampling 

activities. 

Velocity I Volumetric Flow Rate 

Volumetric flow rates were determined during each isokinetic test run. The following 

QC steps were adhered to during these tests: 

Reported duct dimensions were checked by physical measurements to determine 

cross-sectional duct area. 

Pitot tube coefficients were determined based on physical measurement techniques 

as delineated in Method 2 

The Type-S pitot tube was visually inspected before and after sampling. 

The pitot tube was installed on the sampling probe with the proper orientation and 

spacing from the sampling nozzle. 

Before each series of tests, thermocouple readings for the silica gel impinger exit 

temperature was checked against an N.I.S.T. traceable thermometer. 

The oil manometer was leveled and zeroed before each test run. 

Both legs of the pitot tube were leak-checked before and after sampling. 

Proper orientation of the pitot tube was maintained while making measurements. 

The roll and pitch axis of the pitot tube was maintained at 90 o to the flow. 

An average velocity pressure reading was recorded at each point instead of 

recording extreme high or low values. 

The pitot/manometer umbilical lines were inspected before and after sampling for 

moisture condensate. Lines were cleared if moisture was found. 

43 
Molecular Weiqht Determination-Fyrite Analysis 

The carbon dioxide and oxygen concentrations were determined using EPA Reference 

Method 3. A sample of the flue gas was extracted from the gas stream during each test. 

The samples were analyzed with a Fyrite gas analyzer. The following QC steps were 

adhered to during these tests: 

The sampling train was leak checked before and after each samples was taken, 

The samples were run in triplicate for accuracy. 

Standardization was performed to audit the reagents and the operators technique. 

A known mixture of CO2 and 02 was analyzed and repeated with 3 consecutive 

values +/- 0.5 percent of the known value, 

Two NIST traceable gas cylinders were run against the instrument to audit the 

accuracy of the analyzer and the analyzer operator technique. One cylinder 

contained 2 to 4 percent O2 and 14 to 18 percent CO2. The second cylinder 

contained 2 to 4 percent CO2 and about 15 percent 02. 

Moisture Determination 

Stack gas moisture content (Bws) was determined by dividing the mass of moisture 

collected by the impingers or stainless steel condenser and silica gel impinger by the 

standardized volume of gas sampled. The following QC steps were adhered to during 

these tests: 

The indicating silica gel was fresh for the first run and periodically inspected and 

replaced during runs, if needed. 

The analytical balance was placed in a clean, motionless environment for weighing. 

The balance was leveled and zeroed if necessary before each weighing. 

Preliminary silica gel impinger-tare weights and postlrun weight•were weighed•o 

the nearest 0.1 g. 

Before each series of tests, thermocouple readings for the silica gel impinger exit 

temperature were checked against an N.I.S.T. traceable thermometer. 

The silica gel impinger gas temperature was maintained below 68°F and recorded 

at every traverse point. 

Each impinger was wiped of surface moisture before post-run weighing, 

The volume of liquid captured was measured using a graduated cylinder with 1- 

milliliter increments. 
Sulfur Dioxide Determination-Instrumental Analysis Method 6C 

The sulfur dioxide concentrations were determined using EPA Reference Method 6C. A 

sample of the flue gas was extracted from the gas stream during each test. Moisture 

was removed form the sample and was analyzed on a dry basis with an Instrumental 

gas analyzer. The following QC steps were adhered to during these tests: 

Only analyzers that have a resolution or sensitivity of at least < 2.0% of full-scale 

range are used. 

Upon the SO2 analyzers initial use in the field, an interference check was 

conducted. 

The reference calibration gases used in this test program are certified following 

EPA Protocol Number 1 analysis. Copies of the calibration gas certifications are 

included in the instrument calibration section. 

The high level gas was equal to the calibration span gas. 

The mid level gas was between 40 and 60 % of the calibration span gas. 

The low level gas was < 20% of the calibration span gas. 

In accordance with EPA Method 3A a three-point (i.e., zero, mid-, and high-range) 

analyzer calibration error was conducted on each reference analyzer prior to 

initiating the compliance testing. These checks were conducted (after final 

calibration adjustments were made) by injecting the calibration gases directly into 

each gas analyzer and recorded the responses. 

The analyzer calibration error was less than + 2.0% or _+ 0.5 ppm of the calibration 

span gas for the zero, mid-range, and high-range calibration gases. 

The probe material was stainless steel. 

The probe, filter and sample line temperature was maintained above the dew point 

by heating, prior to sample conditioning. 

The sampling system bias was less than + 5.0 % or of the calibration span gas for 

the zero and upscale calibration gases • 0.5 ppm absolute difference). 

The system response time .was calculated during the initial sampling system bias. 

The drift for either the low-level and mid-level or high-level gases was less than + 

3.0% or of the calibration span gas (+ 0.5 ppm absolute difference). 

The sampling system was purged > 2 times the system response time before each 

test run. 

Sample flow rate was maintained within 10% during the entire test period. 

Data is recorded at 1-minute intervals. 

45 
All data collected was within the calibration span gas. 

Carbon Monoxide Determination-Instrumental Analysis- Method 10 

The carbon monoxide concentrations were determined using EPA Reference Method 

10. A sample of the flue gas was extracted from the gas stream during each test. 

Moisture was removed form the sample and was analyzed on a dry basis with an 

Instrumental gas analyzer. The following QC steps were adhered to during these tests: 

Only analyzers that have a resolution or sensitivity of at least < 2.0% of full-scale 

range are used. 

Upon the CO analyzers initial use in the field, an interference check was conducted. 

The reference calibration gases used in this test program are certified following 

EPA Protocol Number 1 analysis. Copies of the calibration gas certifications are 

included in the instrument calibration section. 

The high level gas was equal to the calibration span gas. 

The mid level gas was between 40 and 60 % of the calibration span gas. 

The low level gas was < 20% of the calibration span gas. 

In accordance with EPA Method 3A a three-point (i.e., zero, mid-, and high-range) 

analyzer calibration error was conducted on each reference analyzer prior to 

initiating the compliance testing. These checks were conducted (after final 

calibration adjustments were made) by injecting the calibration gases directly into 

each gas analyzer and recorded the responses. 

The analyzer calibration error was less than _+ 2.0% or + 0.5 ppm of the calibration 

span gas for the zero, mid-range, and high-range calibration gases. 

]'he probematerial was stainless steel. 

The probe, filter and sample line temperature was maintained above the dew point 

by heating, prior to sample conditioning. 

The sampling system bias was less than + 5.0 % or of the calibration span gas for 

the zero and upscale calibration gases (_?_ 0.5 ppm absolute difference). 

The system response time was calculated during the initial sampling system bias. 

The drift for either the low-level and mid-level or high-level gases was less than + 

3.0% or of the calibration span gas (_?_ 0.5 ppm absolute difference). 

The sampling system was purged > 2 times the system response time before each 

test run. 

Sample flow rate was maintained within 10% during the entire test period. 
Data is recorded at 1-minute intervals. 

All data collected was within the calibration span gas. 

Hvdroqen Chloride (HCl) 

Accurate concentrations are dependent on the collection of HCI-HF by the train and 

recovered after sampling, and the standardized gas sample volume measured. QC 

procedures that were followed so that representative particulate data was collected by 

the sampling system were: 

Only clean, well-maintained sampling equipment was used. 

Sampling ports were inspected and cleaned prior to sampling. 

All equipment was calibrated according to EPA standards. The dry gas meter was 

fully calibrated within the past 12 months using a set of calibrated orifices. 

The sampling train components exposed to sample gas were constructed of glass 

or Teflon. 

Accurate barometric pressure was recorded at least once per day. 

The dry gas meter thermocouples were compared to ambient temperature prior to 

the test run as a check on operation. 

Pretest and post-test leak-checks were completed (must be less than 0.02 cfm or 

4% of the average sampling rate). 

Before each series of tests, thermocouple readings for meter temperature, filter 

hotbox, probe, and filter exit temperatures were checked against an N.I.S.T. 

traceable thermometer. 

Readings of the dry gas meter, meter orifice pressure (/•H), meter temperatures, 

filter hotbox temperaturesrprobe•temperatures_and-filter_exit_temperatures•were 

taken at every traverse point. 

Probe and filter temperatures were monitored and maintained at a temperature 

greater than 248°F. 

The gas meter was read to the thousandth of a cubic foot for the initial and final 

readings. 

The sampling velocity through the nozzle was maintained within 10% of the stack 

gas velocity (isokinetic sampling rate at 100+10%). 

A blank was collected for laboratory analysis. 

Prior to the initial run a y-factor check was performed to ensure that the meter was 

operating according to the original calibration to within 3% of the original y-factor. 
For the post-test calibration the alter, native Method 5 post-test calibration 

procedures were used (Emission Measurement Center Approved Alternative 

Method ALT-009), 

,! 
ENTEC SERVICES, INC 

FIELD QA/QC CHECKLIST 

SOURCE TESTED: 

PERMIT NUMBER: 

TEST METHODS USED: 

CONTROL AGENCY: 

ENTEC PERSONNEL: 

LOCATION: 

TYPE CONTROL DEVICE: 

PERMIT LIMITS: 

MODIFICATIONS TO METHOD: 

ON SaTE REPRESENTATIVE: 

PLANT CONTACT: 

Was Calibration Data on site? (Methods 1-5 / CEMS CAL Gas) 

Was Stack Diameter I Area & Traverse Points vedfied on field data sheets? 

YE._3S 

5. 

7. 

Was a 10-minute Meter Orifice Check performed? 

Results of check 

Were Temperatures Verified w/NIST Traceable Thermometer? 

Was Preliminary Traverse wl Cyclonic Flow verification performed? 

Was previous test data on source used to determine K factor? 

Was Probe & Hot Box Temperatures maintained at 248 +/- 25 ° F? 

If not, explain 

,K 

x 

8. Was Filter Outlet Temperature maintained at 248 +/- 25 ° F? 

IfnoLexplain•.•,a•_ •=/•"F •P•¢" _•A 

9. Was Orsat or Fyrite leak checked and standardization perfo_rr•ed as required? 

Ambient 02 Reading ,,• e.•' % Ambient CO2 Reading .j•r % 

10. Was Tedlar Gas Sampling Bags used? If not, explain •r'• 7 •- 

eVV•re they leak-ch•? Y or N / 

11. Were Pitot Leak Checks performed & recorded on each field data sheet? 

Pitot inspected?(•or N Noted Visual Defects? /VoM_ 

12. Was Meter Leak Checks performed & recorded on each field date sheet? 

13. Was Nozzle Diameter measured & recorded o• each field data sheet? 

Nozzle inspected? •or N Noted Visual Defects? /V'e,.t. 

14. Was Silica Gel Verified, and recorded for each test run? 

Percentage Used dudng test Run No.'s 1: / • 2: ,/•' 3: / 

15. Was Acetone Lot Number)•,•ed and rec, orj•ed•on Field Data Sheet 

3ignature (Test Team Leader): 2'• //•• Date: 

As required: Control room data supplied by: •-"•,•_ • ,•r 

Revision 2 December 2005 DLB 

49 

via on-site, email, or fax. 
ENTEC SERVICES, INC. 

METER ORIFICE AND TEMPERATURE CHECKS 

Client: "•re/ •ri•_12, 

Date: •- •-o"7 

Meter Box Number:. •- 13 

Odginal &H@" /,•'oo 

Location: /.•/'=m •'J'l•./j •' 

Barometric Pressure: • • .•'7 "Hg 

Original Y: O. 

Bi-Annual Calibration Date: 

RUN METER FOR EXACTLY 10.0 MINUTES 

Orifice Manometer 

Reading &H equal to 

•H @ 

Dry Gas Volume, ft :• Dry Gas Meter Inlet 

Temperature, °F 

Dry Gas Meter Readings: Initial Final Initial Final 

/, •'0 ,•.. •'oo 

Total Volume: 

Vm = Volume of Dry Gas Meter 

(,3 

Average: 

&5 

Tm= Average Temperature of Dry Gas Meter in degrees Rankin (+460) 

PBarm = Barometric Pressure 

Dry Gas Meter Outlet 

Temperature, °F 

Initial Final 

(,3 

Average: 

Yc = 10NmX •/{ 0.0319 X mm/PBarm} 

= 10/( •7.(.,•/o )X•/{0.0319X( 'E,,•¥ )/(,•8.•'7 )} 

=(/. "•oq ) x (o.7•/ )= o.q•'4 

Is Y¢ < +/- 3% of Original Y ?./V• • 

Thermocouple Check (all temperatures are in o F) NIST Traceable ID •'/2_.7-.7q/• • 

Thermocouples I I.D. 

..Stack (Post Required) 

Probe / -•'S •- •&• 

Filter Box / • •-/z/ 

Filter Exit l'T'(_.- / ff" •-• 3' 

Meter Outlet / •'- ,/• • / 

Impinger Exit / (•/L/• / • / 

Other / 

Field Checks Performed By (Signature): 

Ambient Temp. Reference Temp. 

•0 

Acceptance Range OK? 

+/- 7.5 o 

+/- 5.4 o 

+/- 5.4 o 

+/-2.0 o 

+/- 5.4 o 

+/-2.0 o 

+/- 5.4 o 

Revision September 2005 DLB 

5• 
N/TEC 

SERVICES, INC. 

ORSAT STANDARDIZATION 

Client: 

Source: "•.'•Ia •" 

Orsat/,• Leak Check: 

Date of Test: 

Date of Standardization: •-/Z-o 7 

Orsat / • ID #: 

Vendor 

Gas 

Calibration Gases 

Tank I 

02 O• 

Concentration, (%) 

Carrier Gas 

Container Type 

Cylinder ID # 

Date of Expiration 

•S 

Tank 2 

COz 

•5 

Tank 1 

1 

Actual Net 

co, #_,.o i•.o 

2 

Actual Net 

/•.0 

3 

Actual Net 

/•.0 

Average 

Net 

Volume 

Known 

Value 

Difference 

0.007 

Tank 1 

2 

Actual 

COz 3.o 

02 

Net 

/•'.o 

2 

Actual 

/•'.o, 

Net 

3 

Actual 

/•o 

Net 

•.o 

/f.o 

Difference must. be less than ;• •.•/• ANALYST (Signature I Date): 

Average 

Net 

Volume 

Known 

Value 

002. 

Difference 

a.ooZ 

51 
Calibration complies with 

ISO 17025 

Traceable® Certificate of Calibration for Lollipop 

Instrument Identification: 

Cert. No.:4378-1154572 

Thermometer 

Model: 06-664-27 S/N: 51227962 Manufacturer Control Company 

Standards/Equipment: 

Description 

Then•istor Module 

Temperature Probe 

Temperature Probe 

Temperature Calibralion Bath TC179 

Temperature Calibration Bath TC 191 

SeriaJ Number Due Date 

A17118 7130105 

128 10118/05 

157 7/26/05 

A45240 

A42238 

NIST Traceable Reference 

A4730038 

A4A12029 

A4715025 

Certificate Information: 

Technician: 104 Procedure: CAL-03 

Test Conditions: 24.0°C 48.0 %RH 1017 mBar 

Cal Date: 7/22/05 Ca/Due: 7/22/07 

Calibration Data: (New Instrument) 

u.it(s• Nominal 

°C 

"c 

Nominal As Left In TOl Min 

100.010 99.6 Y 99.6 

Max ±uc 

0.4 0.059 

100.4 0.059 

TUR 

>4:1 

>4:1 

This Instrument was calibrated using Instruments Traceable to National Institute of Standards and Technology. 

Wallace 8e(ry. Technica• 

Maintaining Accuracy: 

In Out Opimon cahbrate(I your Lollipop Therrr:,•meter should maintain =ts accuracy. There exact way to •lelem'•ne how long cah•ration w=ll be mamlained. Lo•lipol• Ther•l"etets c•ange httle. •f an), at all. but be affected by aging, temperature, shcck, and COntarr•'nabOn. 

Recalibration: 

For factoR/cahOra£=cn and re-certification Iraceable to Nelioaal tnsl=tule of Standards and Techno•cgy contact Conv(•! Company. 

CONTROL COMPANY 4455 Rex Road Friendswood, TX 77546 USA 

Phone 281 482-1714 Fax 281 482-9448 service@control3.com www.control3.com 

Control Ccrrpany ISO 17025 Cal=bratien Laboratory Acctedded by (A2LA) American Assoc,allon for Labora(o•j Accreddat•o•. Cen•ca=e No. 750.0 

ConVo• Ccmpa•y ISO 9001 Ouahty Cedified by (DNV) Oet Ncrs•e Ve•tas, Centflcace No. CERT-0•805-AQ-HOU. 

52 
Certificate of Analysis 

Date of Analys•s: 

Custon•er Na•e: 

Grade of Product: 

7/14i2005 

PRIMARY STANDARD 

Reference N,Jmber: 

Part Number" 

87-t 10858887-5 

X03N•82P15AC226 

C_ylinder Number 

CC2t4t39 

.Compot•ent RequeSte• Actual[ 

CARBON DIOXIDE 3.000 % 3.002 % 

OXYGEN • 5.00 % t4.97 % 

NITROGEN Balance Balance 

Notes: 

Re•at_!,,f.e..,Unc .e..t!.alD..ty of A..n_a|ytical! va•e:. +t, 1% of component or +f- 0,02% of absolute, wNch ever is lower. 

Primaj•/Standard gas mixtures are traceabte to N.I.S.T weights and/or N,I.S,T gas mixture 

reference materials, I / 

Ap•c, va.i Si.gnalute j •'L...•... 

53 
Certificate of Analysis 

Date o• Analys•s: 

Custo•er Name 

Grade of Product: 

7•"t4J2005 

PRIMARY STAN DARD 

Refere•ce Nu•'#ber" 

Part Number: 

87-i t0858887-4 

XO3NI81 P15AC225 

CC2"t4•47 

Component Requested 

Concentration 

Actua| Concentr_•_ti_o•R 

OXYGEN 3.00(} % 2.993 % 

CARBON DIOXIDE t6.00 % 15,£7 % 

NITROGEN Ba•anc• 8afar•ce 

Notes: 

Relative Uncertait•t3t. of.Analytical Value: +!- 4% of component or +t- 0,02% of absolute, 

which ever is lower, 

Primary Standard gas mixtures a• traceable to N.I.S.T weights and/or N.f.S.T gas mixture 

reference •tedals. 

54 
E 

E 
ENTEC SERVICES, INC 

FIELD QA / QC CHECKLIST 

Method 6C Sulfur Dioxide 

CLIENT: "•:•:•.•-•..• LOCATION: I.•--• C•-•-• 

SOURCE TESTED: "--I•T,-•- F •%,&.P---E. •PE CONTROL DEVICE: 

TEST METHODS USED: • • I• • MODIFICATIONS TO METHOD: 

Was valid Interference Check (sum of responses < 2.5 % of calibration span) on site? 

2 Was valid Certificate of all Protocol 1 calibration gases on site? 

3 Was the High-level gas equal to the calibration span ? 

4 Was the Mid-level gas between 40 and 60 % to the calibration span ? 

5 Was the Low-level gas < 20 % of the calibration span ? 

6 Was the sample kept above the dew point by heating pdor to the sample conditioner ? 

7 Was the Analyzer Calibration Error within +/-2 % or +/- 0.5 ppm of the calibration span for all 

calibration gases ? 

8 Was the System Bias within +/-2 % or +/- 0.5 ppm of the calibration span for all 

calibration gases ? 

9 Was the System Response Time Calculated during the initial sampling system bias check? 

What was the System Response Time ? •.E;> Seconds 

10 Was the Drift within +/-3 % or +/- 0.5 ppm of the calibration span for the low-scale and upscale 

gases ? 

11 Was the sampling system purged > 2 times the system response time before each test run? 

12 Was the minimum time at each sampling point > 2 times the system response time ? 

13 Was the sample flow rate within 10 % of the flow rate established during the system response time 

check for each run ? •1 I.•,"• Flow rate: ,L/, • liters/minute 

14 Was a stratification test performed before the first run ? 

What were the results of the stratification test? 

All points were: Within +/- 5 % or +/- 0.5 ppm of mean for 1-point sampling (unnstratified) 

Within +/- 10 % or +/- 1.0 ppm of mean for 3-point sampling (minimumally stratified) 

Some points were > 10 % or 1.0 ppm of mean for 3-point sampling (stratified) 

15 Was a Multi-point or 3 point probe used ? 

16 Was the flow rate from each point verified to be within 10 % of the mean flow rate for each run ? 

17 Were all data points recorded in at least 1 minute averages? 

18 Was the average concentration foleach run < the calibration span ? 

Signature (Test Team Leader): Date: 
ENTEC SERVICES, INC 

FIELD QA / QC CHECKLIST 

Method 10- Carbon Monoxide 

CLIENT: 

SOURCE TESTED: "-'J•T,..• F- -•'i•.,• 

TEST METHODS USED: 

LOCATION: 

TYPE CONTROL DEVICE: 

MODIFICATIONS TO METHOD: 

Was valid Interference Check (sum of responses < 2.5 % of calibration span) on site? 

2 Was valid Certificate of all Protocol 1 calibration gases on site? 

3 Was the High-level gas equal to the calibration span ? 

4 Was the Mid-level gas between 40 and 60 % to the calibration span ? 

5 Was the Low-level gas < 20 % of the calibration span ? 

6 Was the sample kept above the dew point by heating prior to the sample conditioner ? 

7 Was the Analyzer Calibration Error within +/-2 % or +/- 0.5 ppm of the calibration span for all 

calibration gases ? 

8 Was the System Bias within +/-2 % or +/- 0.5 ppm of the calibration span for all 

calibration gases ? 

9 Was the System Response Time Calculated dudng the initial sampling system bias check? 

What was the System Response Time ? 1 •t:> Seconds 

10 Was the Drift within +/-3 % or +/- 0.5 ppm of the calibration span for the low-scale and upscale 

gases ? 

11 Was the sampling system purged > 2 times the system response time before each test run? 

12 Was the minimum time at each sampling point > 2 times the system response time ? 

13 Was the sample flow rate within 10 % of the flow rate established during the system response time 

check for each run ? •,[ • Flow rate: •,'• liters/minute 

14 Was a stratification test performed before the first run ? 

YE•S NO 

What were the results of the stratification test? 

All points were: Within +/- 5 % or +/- 0.5 ppm of mean for 1-point sampling (unnstratified) 

Within +/- 10 % or +/- 1.0 ppm of mean for 3-point sampling (minimumally stratified) 

Some points were > 10 % or 1.0 ppm of mean for 3-point sampling (stratified) 

15 Was a Multi-point or 3 point probe used ? 

16 Was the flow rate from each point verified to be within 10 % of the mean flow rate for each run ? 

17 Were all data points recorded in at least I minute averages? 

18 Was the average concentration for each run < the calibration span ? 

19 Was an integrated bag sample used to analyze CO ? 

Signature (Test Team Leader):'--•• •-.,-•_ Date: 

5? 
Date 7/16/2004 

Analyzer Model West. Research 721AT 

Component SO2 

Analyzer Serial No. 7700-1 

Span 0-1000ppm 

Cylinder ID Test Gas 

SG9120994 SO2 

Interference Response Test 

Concentration Analyzer Response Difference % of Span 

213 203 -10 -1.00 

SG9120994 CO 495 

SG9120994 CO= 9.76 

SG9120994 02 20.79 

Total 10 1.00 

*Specification (EPA Method 20)" Sum of interference responses must not exceed 2% of span 

% of Span Analyzer Response X 100 Instrument Span 

58 
Date 

Analyzer Model 

Component 

Analyzer Serial No. 

Span 

7/16/2004 

API-300 

Carbon Monoxide 

866 

0-1000 ppm 

Interference Response Test 

Cylinder ID 

CC123630 

CC123630 

CC123630 

CC172148 

CC172148 

Test Gas 

SOz 

CO 

02 

CO2 

Concentration 

200 

5OO 

20.9 

10.08 

Analyzer Response 

499 

Difference 

-1.0 

% of Span 

-0.10 

O2 10.05 

Total 1.00 0.10 

*Specification (EPA Method 20) Sum of interference responses must not exceed 2% of span 

% of Span Analyzer Response X 100 Instrument Span 

59 

ENTEC SERVICES, INC. 

METHOD 26A SAMPLE RECOVERY DATA SHEET 

Client / Location: _Boral Bricks Sampling Date(s):_3-14-2007 

Run No.: 1 

Impingers 1 

Recovery Date: 3/14/2007 

2 3 4 

Recovered By: LB 

6 Silical Gel 

Final Wt. 

Initial Wt. 

Net Weight 

180 

100 

80 

122 

t00 

22 

105 t03 

100 100 

5 3 

873.9 

860.9 

Description of Impinger Contents: 

Description of Particulate on Filter: 

Silica Gel Color: 

Filter I.D. Number: 

Probe Rinse Container No.: 

Impingers 1(0.1N HzSO4)ContenLs Container No.: 

Impingers 2(0.1N H2SO4)Contents Container No.: 

Impingers 3(0.1N NaOH)Contents Container No.: 

Impingers 4(0.1N NaOH)Contents Container No.: 

Run No.: 

Impingers 

2 Recovery Date: 

1 2 3 

Total Moisture 123.0 Grams 

Sealed: Y N 

Percent Spent: /' •" % 

Filter Container No.: 

Liquid Level Marked I Sealed: Y N 

Liquid Level Marked Sealed: (•) N 

Liquid Level Marked Sealed: Y N 

Liquid Level Marked / Sealed: Y N 

Liquid Level Marked I Sealed: Y N 

3/14/2007 

4 5 

Recovered By: LB 

6 Silical Gel 

Final Wt. 

Initial Wt. 

Net Weight 

179 127 

100 100 

79 27 

105 

100 

5 

104 

100 

4 

817.9 

Description of Impinger Contents: 

Description of Particulate on Filter: 

Silica Gel Color: 

Filter I.D. Number: 

Probe Rinse Container No.: 

Impingers 1(0.1N H=SO•)Contents Container No,: 

Irnpingers 2(0.1N HiSO•)Contents Container No.: 

Impingers 3(0.1N NaOH)Contents Container No.: 

Impingers 4(0.1N NaOH)Contents Container No.: 

Total Moisture 130.2 Grams 

Sealed: Y N 

Percent Spent: //•" % 

Filter Container No.: 

Liquid Level Marked / Sealed: Y N 

Liquid Level Marked / Sealed: •) N 

Liquid Level Marked Sealed: Y N 

Liquid Level Marked I Sealed: Y N 

Liquid Level Marked I Sealed: Y N 

Run No.: 3 

Impingers 1 

Recovery Date: 31t412007 

3 4 

Final Wt. 

Initial Wt. 

Net Weight 

182 136 

100 100 

82 36 

100 105 

100 100 

0 5 

Recovered By: LB 

6 Silical Gel 

885 

Description of Impinger Contents: 

Description of Particulate on Filter: 

Silica Gel Color: /H •'•,• • 

Filter I.D. Number: 

Probe Rinse Container No.: 

Impingers 1(0.1N H=SO•)Contents Container No.: •.• 

Irnpingers 2(0.1N HzSO•)Contents Container No.: 

Impingers 3(0.1N NaOH)Contents Container No.: 

Impingers 4(0.1N NaOH)Contents Container No.: 

BLANKS: Probe Rinse: 

Total Moisture 134.1 Grams 

Sealed: Y N 

Percent Spent: / • % 

Filter Container No.: 

Liquid Level Marked Sealed: Y N 

Liquid Level Marked / Sealed: • N 

Liquid Level Marked Sealed: Y N 

Liquid Level Marked I Sealed: Y N 

Liquid Level Marked Sealed: Y N 

0.1N H2S04: X 0.1N NaOH: Filter: 
ENTEC SERVICES, INC 

LABORATORY SAMPLES QA / QC CHECKLIST 

SOURCE TESTED: 

ANALYSIS: IAr--I 

RECOVERED BY: 

SAMPLING DATE(S): 3-/z-i'- 07 

METHOD(S): ,/"• •, 

RECOVERY DATE: • -/•-(}7 

Description of Impinger Content F 

Test Run No.'s 1: •/¢•r" 2: •i•r 3: 

Impinger Contents Container Number: 

Test Run No.'s 1: • "/ 2: J'2.- 2. 3: 

Samples Sealed and Stored in Secure Container? (•3or N 

Liquid Level Marked? •or N 

Filter ID Number:. 

Test Run No.'s 1: /L/.• 2: /•tA 3: 

Description of Particulate on Filter: 

Test Run No.'s 1: A,/,• 2: /'I/A 3: 

Filter Container Number: 

Test Run No.'s 1: N,,• 2: A],,• 3: 

Samples Sealed and Stored in Secure Container? ¥ or N 

Probe Rinse Container Number: 

Test Run No.'s 1: /D/A 2: ,•.iA 3: 

Samples Sealed and Stored in Secure Container?. Y or N 

Liquid Level Marked? ¥ or N 

Probe Rinse Reagent: •',• Lot Number. 

Laboratory Blanks: 

Probe Rinse: Impinger: • Filter: 

Were samples analyzed by Entec Services, Inc.? Y or N 

If not, Laboratory Performing Analysis: 

Other: 

*** If using outside laboratory services please fill out the following chain of custody. 

Signature: /..,.__ /• Date" 

)tint Name:, •.-,,..,-... ,2• Time (24hr): 

Signature (Project 

• 

Manager or,T• •• 

Rev•ien 2 Septem•r 2005 TLj 62 
Environmental Tesang Laboratory, 

305 Crawford $•reet 

Fairfield, • 35064 

(205) 785-1750 

Lab Invoice #: 24131 

•lient: Mr. Tom Lotz 

Entee Services, Inc. 

16D Commerce Avenue 

Hueytown, AL 35023 

Date: March 22, 2007 

Project Name: Boral Bricks Project Number: 27109 

Project Location: N/A P.O. Number: N/A 

Sample Matrix: Liquid 

Sampled By: L. Beane Date Collected: March 14, 2007 

Test Method: 'WIethods for Chemical Analysis of Water and Wastes", EPA-600/3-83. 

LIQUID ASSAYS 

Lab LD.: 7136(; 

Run 1Diff Run2 Diff Run 3 Diff i!i!•! !|iii!•!i!it!ii!i•iiiiliiii!•iii!iiiii•.•t.!iiiii 

.•.............._. ;:;:;:: :•:• 

TotalHCL 11.4210.7810.81 ]O-02Totalmg / 300.0 [21-Mar-07[ 1345 ] MD 

i I 1345 I MD 

-.V..°.!....•.....e............................... I. 3..9.0. ! .4!.5. I. 3..7.5. .I. .m L [iiiiiiiiiii!i!i|21-Mar-07| 1345 | 

L :i i:i ::i:i :i:i:i:i:i:i:i:•:i:i:i:i: ::::::::::::::::::::::::::::::::::::::::::::::::: i:i: :i:i:i:i:i:•:i:" !:!iii•il 

::::::::::::::::::::::::: :::::::::::::::::::::: !::i !:i!:i:i iii!! ::i ii iiiiii ::: 

l•eld LD.: :::::::::::::::::::::::::: :i:!:i:i:!:!:!:i:i:i:i:i:i :! i:i!i i:i:!:i:i:i:i:..:i:i:!:i:i:!:i:i:i:i:i:i:, !:!:i:!:i:!:i:!:i: :i::: ::::::::::::: ::::::::i:::i:!: 

! | 

• ot•'•C• •O• li::ii!!ili!ii!iiii::iiiiiiiitiiiiiii!iiiiiiiiiiii!i!::i:: 0.02mg/L 300.0 21-Mar-07 1345 MD 

TotalHF BDL 

!!i!ii!i!iiiiiiiiiii::!iii!iitliii!!iiiiiiiiiiii!i!iiiii 0.02mg/L 300.0 21-Mar-07 1345 lVlD !!i:i:i:i:i:i:i:i:i:i:i:i:il:i:i:i:i:i:i:i:i:i:i:i:i:i :::::::::::::::::::::::::: 

Detection limit, practical 

BDL=Bdow Detection Limit 

Respectfully submitted, 

President 

ADEM Laboratory Certification I.D.# 40710 

63 
Environmental Testing Laboratory, 

305 Crawford S/feet 

Fairfield, AL 35064 

(•os) 7ss4•so 

•.lient: Mr. Tom Lotz 

Entec Services, Inc. 

16D Commerce Avenue 

Hueytown, AL 35023 

Lab Invoice #: 24131 

Date: March 22, 2007 

Project Name: 

Project Location: 

Sample Matrix: 

Sampled By: 

Lab Analyst: 

Test Method: 

Boral Bricks Project Number: 27109 

N/A P.O. Number: N/A 

Liquid 

L. Beanc Date Collected: March 14, 2007 

MD Date/Time Analyzed: March 21, 2007 @ 1345 

'•VIethods for Chemical Analysis of Water and Wastes", EPA-600/3-83. Method 300.0. 

QUALITY CONTROL DATA 

ERA Minerals Reference Control Lot #P128506 

Chloride Assayed: 114 mg/L 

Flouride Assayed: 1.89 mg/L 

Range: 101-124 mg/L 

Range: 1.47-1.97 mg/L 

Respectfully submitted, 

Presid•t 

ADEM Laboratory Certification I.D.# 40710 

64 
ENTEC SERVICES, INC. 

Chain of Custody 

Client 

Contact: 

Phone No: 

Lab Name •//'///•0•/• 

Lab Invoice # c• •/gl. • / 

Entec Job No. # 

PO # 

Samples Collected by: 

Send Results to: 

Phone I Fax Results To: 

Tom Lotz lient 

205-491-6-676• 

Time :::', "" ,Analysis. • Method •: .! Preservative 

PrintName: ///,•,•'/•// •,• ITime(24hr): O• "/ '0 0 PrintName: ,/'>•/ 

-/:.." :'i :I.RE.L.!NQU.pHEDB :DATE/TIM E 

Signature: /•; ,,;/'•'•, Y'• Date: ,•//L•/i• Signature: 

Print Name: 

• •FJ • • Time (24hr): O • • Print Name: 

RECI,.E•EDBY. 

SPECIAL INSTRUCTIONS I COMMENTS: 

65 
ENTEC SERVICES, INC. 

Chain of Custody 

Client 

Contact: 

Phone No: 

Project# 

Lab Name 

Lab Invoice 

Entec Job No. 

Samples Collected by: 

Send Results to: 

Phone / Fax Results To: 

Tom Lotz •_•O•r Client 

205-491-6676 

Lab I.D. Field I.D. Date Time Analysis I Method ..Preservative 

RELINQ•IISHED 

Signature: 

Print Name: /•'-.• •-•, ,•/ 

DATE I TIME RECIEVED BY 

Date: 3 116 I07 Signature: 

Time (24hr): •/• [:1• Print Name: / -•,%•///• • •'-•,Y •,•a•,t•-) 

RELINQUISHED BY DATE I TIME RECIEVED BY 

Signature: 

Print Name: 

Date: 

Time (24hr): 

/ / Signature: 

Print Name: 

SPECIAL INSTRUCTIONS COMMENTS: 

66 


Analyzer Calibration Error 

'est Performed For: 

Boral Bdck 

Union City, Oklahoma 

Kiln DIFF Exhuast 

Compliance 

Date:3114107 

Carbon Monoxide Monitor 

Calibration Span: 227.0 ppm 

Cylinder Reference Gas 

Number Concentration 

% of Analyzer 

Calibration Span Response 

Test Performed By: 

Entec Services, Inc. 

Birmingham Division 

Test Trailer 901 

Mr. Lynn Beane 

Runs 1-3 

Method 10 

Serial Number: API 300 SN 866 

Difference Calibration 

Error (%) 

Absolute 

Difference 

XC001059B 0.0 ppm 0.00 % 0.0 ppm 0.0 ppm 0.00 % 0.0 ppm 

CC14042 118.2 ppm 52.07 % 117.9 ppm -0.3 ppm -0.13 % 0.3 ppm 

CC126574 227.0 ppm 100.00 % 227.4 ppm 0.4 ppm 0.18 % 0.4 ppm 

Sulfur Dioxide Monitor 

Calibration Span: 221.0 ppm 

Cylinder Reference Gas % of Analyzer 

Number Concentration Calibration Span Response 

Method 6C 

Serial Number: WR 721AT SN 7700-1 

Difference Calibration 

Error (%) 

SG917038 0.0 ppm 0.00 % 0.0 ppm 0.0 ppm 0.00 % 

SG9166186 90.7 ppm 41.04 % 90.0 ppm -0.7 ppm -0.32 % 

CC91160 221.0 ppm 100.00 % 221.0 ppm 0.0 ppm 0.00 % 

Absolute 

Difference 

0.00 % 

0.70 % 

0.00 % 

69 
aria Drift 
• 0 

0 

E E 

E E 

• 0 

0 • 

o o, 

E E 

E E 

E 

0 0 

o o 

E E 

O. 

• •.. 

0 0 

• 0 

O0 0 

E E 

0 0 

E 

0 0 

0 0 

0 0 

¢..0 

E • 

E 
0 0 

0 •0 

E o. 

E 

0 0 

o o 

O_ 

O_ 

0 0 

03 

r•o o 

o'• o 

o 

I= 
E E 

E E 

o oo 

E E o_ 

E E 

E E 

o 

E E 

o. 

o.. 

o o 

O 

E E 

E E o_ 

E E o. 

73 

3434 Route 22 West, Branchburg, New Jersey 08876 USA 

ISO 9001:2000 

Shipped from: 80 Industrial Drive, Alpha, NJ 08865 

CERTIFICATE OF ANALYSIS EPA PROTOCOL MIXTURE 

PROCEDURE#: GI 

CUSTOMER: Cherokee Instruments Inc. CYLINDER # CC-126574 

SGI ORDER # 0094106 CYLINDER PRES: 2000 PSIG 

ITEM# 3 CGA OUTLET: 350 

P.O.# 7962 

CERTIFICATION DATE: 08/14/06 

EXPIRATION DATE: 811412009 

CERTIFICATION HISTORY 

DATE OF MEAN CERTIFIED ANALYTICAL 

COMPONENT ASSAY CONCENTRATION CONCENTRATION ACCURACY 

Carbon Monoxide 08/04/06 227 ppm +/- 1% 

08/14/06 

227.6 ppm 

227.3 ppm 

BALANCE Nitrogen 

PREVIOUS CERTIFICATION DATES: None 

REFERENCE STANDARDS 

COMPONENT 

Carbon Monoxide 

SRMINTRM# 

GMIS-1 

CYLINDER# 

CC-90770 

CONCENTRATION 

506 ppm 

INSTRUMENTATION 

COMPONENT MAKE/MODEL SERIAL # DETECTOR CALIBRATION 

DATE(S) 

Carbon Monoxide Horiba VIAo510 570423011 NDIR 08114106 

THIS STANDARD IS NIST TRACEABLE. IT WAS CERTIFIED ACCORDING TO THE EPA PROTOCOL PROCEDURES. 

DO NOT USE THIS STANDARD IF THE CYLINDER PRESSURE IS LESS THAN'I$0 PSIG. 

ANALYST: 

• 

C)'/• ¢;•'• 

DATE: 08/14/06 

CHERYL PATINO 

Tel: +1 908-252-9300 Fax: +1 908-252-0811 

www.spectragases.com 

75 
Certificate of Analysis 

Cylinder Number: CC14042 

Cylinder Pressure: 2000.6 PSIG 

Certification Date: 6/27/2006 

Certified Concentrations 

MONOXIDE 

EPA Protocol Gas Mixture 

Reference Number: 

Expiration Date: 

Laboratory: 

83-124068198-5 

6/27/2009 

ASG Port Allen LA 

Component Concentration Accuracy Analytical Principle Procedure 

118.2 PPM +/- 1% NonDispersive Infrared 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. 

Notes: 

Do not use cylinder below 150 psig. Approval Signature 

Reference Standard Information 

TvDe Balance Gas Component 

NTRM 82636 NITROGEN CARBON MONOXIDE 

Analytical Results 

1st Component CARBON MONOXIDE 

1st Analysis Date: 06/20/2006 

R 246.5 S 119.0 Z 0.5 Conc 

S 119.5 Z 0.0 R 249.0 Conc 

Z 0.0 R 249.0 S 120.0 Conc 

AVG: 

,C¥1.Number Concentration 

XC013304B 246.2 PPM 

118,0 PPM 

118.5 PPM 

119.0 PPM 

118,5 PPM 

2nd Analysis Date: 06/27/2006 

241.5 S 116.0 Z0.0 Conc 117.9 PPM 

116.0 Z 0.0 R 242.5 Conc 117.9 PPM 

0.0 R 242.5 S 116.5 Conc 118.4 PPM 

AVG: 118.0 PPM 
Airgas 

Certificate of Analysis: EPA Protocol Gas Mixture 

Cylinder N umber: SG9166186 

Cylinder Pressure: 2000.6 PSIG 

Certification Date: 6/26/2006 

Certified Concentrations 

Component 

SULFUR DIOXIDE 

NITROGEN 

Reference Number: 

Expiration Date: 

Laboratory: 

83-124068198-2 

6126/2008 

ASG Port Allen LA 

Airgas Specialty Gases 

1075 Cinclare 0rive 

Porl Allen, LA 7076"[ 

(225) 388-0900 

FAX: (225) 388-0959 

Concentration Accuracy Analytical Principle Procedure 

90.70 PPM +/- 1% FTIR G1 

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. 

Notes: 

Do not use cylinder below 150 psig. Approval Signature 

Reference Standard Information 

Type Balance Gas 

NTRM 81694 NITROGEN 

Analytical Results 

1st Component SULFUR DIOXIDE 

st Analysis Date: 06/19/2006 

R 0.650 S 0.602 

S 0,603 Z 0.000 

Z 0.001 R 0.650 

Component C¥1.Number 

SULFUR DIOXIDE XC017671B 

Z 0.001 Conc 90.56 PPM 

R 0.650 Conc 90.74 PPM 

S 0.602 Conc 90.62 PPM 

AVG: 90.64 PPM 

2nd Analysis Date: 06/26/2006 

0.650 S 0.603 

0.603 Z 0.001 

0.000 R 0.648 

Z 0.001 Conc 90.63 PPM 

R 0.649 Conc 90.77 PPM 

S 0.602 Conc 90.92 PPM 

AVG: 90,77 PPM 

Concl•'ntration 

98.0 PPM 

7? 
•3434 Route 22 West, Branchburg, New Jersey 08876 USA 

ISO 9001:2000 

Shipp• • 880•i•t'E•iv•pR•p h•l, 0¢•6•886 5 

RECERTIFICATION OF ANALYSIS EPA PROTOCOL MIXTURE 

PROCEDURE #: G2 

CUSTOMER: Cherokee Instruments Inc. 

SGI ORDER • 0079806 

ITEM# 8 

P.O.# 7445 

CERTIFICATION DATE: 11/14/05 

EXPIRATION DATE: 11/14/2008 

CYLINDER # CC.91160 

CYLINDER PRES: 2000 PSIG 

CGA OUTLET: 660 

CERTIFICATION HISTORY 

DATE OF MEAN CERTIFIED ANALYTICAL 

COMPONENT ASSAY CONCENTRATION CONCENTRATION ACCURACY 

Sulfur Dioxide 10/23/03 222.0 ppm 221 ppm +/- 1% 

11/14/05 220.2 ppm 

BALANCE Nitrogen 

PREVIOUS CERTIFICATION DATES: 10/23/2003 by Spectra Gases 

REFERENCESTANDARD• 

COMPONENT SRM/NTRM# CYLINDER# CONCENTRATION 

Sulfur Dioxide GMIS-1 CC-135535 202 ppm 

INSTRUMENTATION 

COMPONENT 

Sulfur Dioxide 

MAKE/MODEL 

Horiba VIA-510 

SERIAL # 

851221093 

DETECTOR 

NDIR 

CALIBRATION 

DATE(S) 

10118/05 

THIS STANDARD IS NIST TRACEABLE IT WAS CERTIFIED ACCORDING TO THE EPA PROTOCOL PROCEDURES. 

DO NOT USE THIS STANDARD IF THE CYLINDER PRESSURE IS LESS THAN 150 PSIG. 

ANALYST: F / 

DATE: 11/14/05 

FRED PIKULA 

Tel: +1 908-252-9300 Fax: +1 908-252-0811 

www.spectragases.com 

78 

SAMPLING AND ANALYTICAL EQUIPMENT CALIBRATIONS 

All of the emission testing equipment used was calibrated according to the procedures 

outlined in the EPA CFR 40 Part 60 Appendix "A" and the Quality Assurance Handbook 

for Air Pollution Measurement Systems, Volume III, EPA-600/4-77-027b. 

Type-S Pitot tube Calibrations 

The pitot tubes used for flow velocity measurement were checked for dimensions to 

verif• a pitot coefficient Cp of 0.84. Documentation of the calibration and calibration 

check for dimensional measurements is provided. 

Saml•linq Nozzle Calibration 

Sampling nozzles were checked visually for nicks or damage and for dimensional 

calibration prior to testing by measuring the nozzle diameter in at least three planes 

using a Vernier micrometer. Measurements must agree to within +0.004-inches. 

Documentation is provided on the individual data sheets. 

Temperature Measuring Device Calibration• 

Each temperature sensor (stack gas, dry gas meter, and impinger exit) and readout 

was calibrated at a minimum of two points over the anticipated range of use against a 

NIST-traceable mercury-in-glass thermometer. All sensors/readouts were calibrated 

prior to field sampling. Stack gas thermocouples must agree within 1.5% (expressed in 

OR) of the reference thermometer through out the entire calibration range. Dry gas 

meter thermocouples must agree within +5.4°F and impinger exit .thermocouples must 

agree within +2°F. Documentation is provided. 

Dry Gas Meter Calibrations 

Dry gas meters were fully calibrated against a set of calibrated orifices. After assemb!y 

and leak checking, the console's pump is allowed to run for 15-minutes to warm up the 

dry gas meter and pump. For a pre-test full calibration, data are collected at five (5) 

orifice manometer (L•H) settings of approximately: 0.32, 0.67, 1.2, 2.0, and 319 inches of 

H20. Gas volumes of at least 5 ft 3 

are used at all the orifice settings and critical 

vacuums were obtained at all of the calibration points. The individual gas meter 
correction factors (y•) are calculated for each orifice setting and averaged. The method 

requires that each of the individual correction factors fall within +2% of the average 

correction factor, or the meter be cleaned, adjusted or repaired and recalibrated. The 

orifice pressure differential (/•H@) that equates to 0.75 cfm of air at 68°F and 29.92 

inches Hg is calculated and along with the average correction factor (y) is marked on 

the meter console. 

Analytical Balance Calibration 

The analytical balance used to weigh particulate filters and desiccated rinse samples is 

calibrated by comparing its readings against NIST Class 1 weights, with acceptable 

agreement within ±0.5 mg. The field moisture gain balance was also compared to NIST 

Class 1 weight, with acceptable agreement within + l gm. 
0 
TYPE S PITOT TUBE INSPECTION DATA SHEET 

LEVEL 

Tube OO 

Certification 

Parameter 

Assembly Level? 

Holes Damaged? 

Obstructed? 

Value 

Yes 

No 

No 

0 

0 

Y 

A 

Z=Asiny 

W=Asin 0 

PA 

PA- PB 

D•- 

Thermocouple Cal. 

Thermocouple Cal. 

Allowable Range 

Yes 

No 

No 

-10 < c•1 < +10 

-10 < c•2 < +10 

-5 < I•1 < +5 

-5 < •2 < +5 

%':' .:''•. 

::", .-• ::..: !-::•: :!..:.";: 

::!::•::::::.. ,..:: ...,:.:,.....•;..• 

90 .•::,!:::.:.;: :.. : .,ii:ii..:,,'.."!..: 

.988 for 114" OD, 0.526 to 0.750 

for 3/8" OD, 0.788 to 1.125 

0 Z =_ < 0.125" 

0 W _< 0.031" 

.494 

.494 

0 

.375 

70 

70 

for 1/4" OD, 0.263 to 0.375 

for 3/8" OD, 0.394 to 0.563 

for 114" OD, 0.263 to 0.375 

for 3/8" OD, 0.394 to 0.563 

-0.063 to 0.063" 

0.188 to 0.375" 

Reference temp. 

Probe Thermocouple 

certify that the Type S pitot tube/probe ID # ESP- 62B meets or exceeds all specifications, 

criteria and/or applicable design features and is hereby assigned a pitot tube calibration factor 

Cp of 0.84 

Certified and Calibrated By: 

Date Certified: 

Lalan R. Kirby 

12/2912006 

Annual Calibration 

83 
ENTEC Services, Inc. 

16-D Commerce Ave.Hueytown, Alabama 35023 

Calibration Date: 1/8/2007 Calibrated by: Tom Lotz 

Annual Thermocouple Calibrations 

•!: ,,-: •;:,...,•.+..•;;; :•: :•+_-:.;• .::-::--...:--;•;..-::.-:. .:i..--.•- ;•;:;•¢::;. ,.-•. ._;. .::, 

Entec Services Temperature **Reference Thermocouple Difference Within 

ID Number Source Temperature Temperature De•lrees F Tolerance 

TC-1 ambient 6O 61 Yes 

TC-2 ambient 60 61 Yea 

TC-3 ambient 60 61 Yes 

TC-4 ambient 60 61 Yes 

TC-6 ambient 60 61 Yes 

TC-7 ambient 60 61 Yes 

ambient 6O 

ambient 

TC-8 60 Yes 

TC-11 60 61 Yes 

TC-12 ambient 60 61 Yes 

TC-13 ambient 60 60 0 Yes 

TC-14 ambient 60 60 0 Yes 

TC-15 ambient 60 61 Yes 

TC-16 ambient 60 61 Yes 

TC-17 ambient 61 62 Yes 

ambient 61 61 

60 

TC-19 Yes 

TC-20 ambient 61 Yes 

TC-21 ambient 60 61 Yes 

TC-22 ambient 60 61 Yes 

TCo23 ambient 60 61 Yes 

TC-24 ambient 61 61 0 Yes 

TCS ambient 60 60 0 Yes 

ambient 

ambient 

ambient 

TCS 2 

TCS 3 

TCS 4 

TCS 5 

TCS 7 

TCS 9 

TCS 10 

TCS 11 

TCS 12. 

TCS 13 

ambient 

ambient 

ambient 

ambient 

ambient 

ambient 

60 

60 

6O 

61 

61 

CI 

61 

61 

61 

61 

61 

60 

60 

6O 

ambient 

TCS 14 ambient 

TCS- 15 ambient 

TCS- 16 ambient 

Fluke Hand Held 

Fluke Hand Held 2 

61 

61 

61 

61 

61 

61 

61 

61 

Yes 

Yes 

Yes 

Yes 

Yes 

Ye• 

Yes 

Yes 

Yes 

Yes 

Yes 

61 61 0 Yes 

61 61 0 Yes 

61 61 0 Yes 

61 60 Yes 

61 0 Yes 

0 Yes 

ambient 

ambient 

Fluke Hand Held 3 ambient 

61 

61 61 

Temperature tolerance within +/- 2 F of acceptable ranges for all thermocouples, 

Note: NIST Traceable Digital Thermometer Serial Number 221243179 was used as reference temperature 
ENTEC Services, Inc. 

16-0 Commerce Ave.Hueytuwn, Alabama 35023 

Calibration Date: 1/2/2007 Calibrated by: Tom Lotz 

:;•'•,.:::,.,•;;.,:;.'•1.•.::.I::•.:,:,'.:::.,:;.;:.:::.;:; :•.;•;•- •- ;-:_; •. •:: •:• •.:•: •.• :•:;:-..: :.•f., Annual Hot Box The•o•uple Calibrations 

111 

Entec Services Temperature **Reference Thermocouple Difference Within 

ID Number Source Temperature Temperature Degrees F To;e•a•ce 

HOTBOX ambient 66 67 Yes 

HOTBOX 2 

HOTBOX 3 

HOTBOX 4 

HOTBOX 5 

HOTBOX 6 

HOTBOX 7 

HOTBOX 8 

HOTBOX 9 

HOTBOX 10 

HOTBOX 11 

HOTBOX 12 

HOTBOX 13 

HOTBOX 14 

ambient 

ambient 

ambient 

ambient 

ambient 

ambient 

ambient 

66 

66 

66 

66 

66 

66 

66 

ambient 66 

ambient 66 

ambient 

ambient 

66 

66 

ambient 66 

ambient 66 

67 

66 

65 

67 

67 

Yes 

0 Yes 

Yes 

Yes 

Yes 

66 0 Yes 

66 0 Yes 

65 Yes 

65 Yes 

67 Yes 

67 

65 

67 

Yes 

Yes 

Yes 

remperature tolerance within +1- 2 F of acceptable ranges for all thermocouples. 

Note: NIST Traceable Digital Thermometer Serial Number 221243179 was used as reference temperature 

85 
ENTEC Services, 

16-D Commerce Ave.Hueytown, .&!•h_•_ma 35023 

Calibration Date: 1/2/2007 Calibrated by: Tqm Lotz 

--- :%-': 

Annual Gooseneck Thermoc•uple Calibrations 

•:.-• 

Entec Services Temperature **Reference Thermocouple Difference 

ID Number Source Temperature Temperature Degrees F 

GN-1 ambient 65 

GN-2 ambient 

GN-3 

GN-4 

GN-5 

GN-6 

GN-7 

GN-8 

GN-g 

GN-10 

GN-11 

GN-12 

GN-13 

GN-14 

GN-15 (Mini HB) 

GN-16 (Mini HB) 

GN-17 

GN-18 (Mini HB) 

GN-19 (Mini HB) 

GN-20 (Mini 

GN-21 

GN-22 (Mini HB 

ambient 

ambient 

ambient 

ambient 

ambient 

ambient 

ambient 

ambient 

ambient 

64 

64 

64 

64 

64 

64 

64 

65 

65 

65 

64 

63 

63 

Within 

Tolerance 

Yes 

Yes 

Yes 

Yes 

0 Yes 

Yes 

Yes 

64 63 Yes 

64 65 Yes 

64 64 0 Yes 

65 

65 

63 

63 

64 

ambient 64 

ambient 64 

ambient 64 

ambient 

ambient 

Yes 

Yes 

Yes 

Yes 

64 64 0 Yes 

64 65 Yes 

64 63 Yes 

64 64 

64 

ambient 

65 

65 

65 

65 

64 

ambient 

ambient 

ambient 

0 Yes 

Yes 

Yes 

Yes ambient 64 

ambient 64 Yes 

Temperature tolerance within +/- 2 F of acceptable ranges for all thermocouples. 

Note: NIST Traceable Digital Thermometer Serial Number 221243179 was used as reference temperature 

Nomenclatu 
NOMENCLATURE 

ACFM 

Bw• 

C. 

C• 

&H 

&P 

dscf 

E/Btu 

F 

K. 

Mn 

M• 

M• 

Pbar 

P• 

P.• 

PMR 

P• 

P•d 

Qstu 

TVlc 

TVwstd 

Tm 

[std 

V•c 

Cross-sectional area of stack, square feet 

Cross-sectional area of nozzle, square feet 

Actual cubic feet of gas per minute at stack conditions 

Proportion by volume of water vapor in gas stream 

Particulate concentration in stack gas, gr/dscf 

Particulate concentration in stack gas, gr/acf 

Pitot tube coefficient 

Pressure drop across orifice meter, inches water 

Velocity head of stack gas, inches water 

Cubic feet of dry gas corrected to standard conditions 

Excess Air 

Particulate Emission Rate, pounds/mmBtu 

F-factor, 9640 dscf/MMBTU's of heat input 

Constant (85.49) 

Total particulate matter collected, mg 

Molecular weight of stack gas; dry basis, Ib/Ib-mole 

Molecular weight of stack gas; wet basis, Ib/Ib-mole 

Percent of isokinetic sampling 

Barometric pressure, inches mercury 

Stack static pressure, inches of water 

Barometric pressure of dry gas meter, in. mercury 

Particulate mass rate, pounds/hour 

Absolute stack gas pressure, inches mercury 

Barometric pressure, standard conditions, 29.92 inches Hg 

Volumetric flow rate, actual conditions, ACF/min 

Volumetric flow rate, standard conditions, scf/min 

Volumetric flow rate, dry standard conditions, dscf/min 

Theoretical water vapor in the gas stream based on saturated stack conditions, proportion 

by volume (dimensionless) 

Theoretical volume of water collected based on saturated stack conditions, ml 

Theoretical volume of water vapor in the gas sample based on saturated stack conditions, 

corrected to standard temperature and pressure, scf 

Absolute average dry gas meter temperature, degree R (460) 

Absolute average stack gas temperature, degree R (460) 

Absolute temperature at standard conditions, 528 R 

Total sampling time, minutes 

Total volume collected in impingers and silica gel, gr 

Vmstd 

Vs 

Ywsgstd 

Wim• 

Ws• 

¥ 

Volume of gas sampled through gas meter, cubic feet 

Volume collected at stack conditions through nozzle, ACF 

Stack gas volume sampled, ACF 

Volume of gas sampled through gas meter, cubic feet 

Average stack gas velocity, feet/sec 

Volume of water vapor in gas sampled from impingers, standard cubic feet 

Volume of water vapor in gas sampled from silica gel, standard cubic feet 

Total volume collected in impingers, gr 

Total volume collected in silica gel, gr 

Dry gas meter calibration factor 

89 
TEST CALCULATIONS 

EQUATIONS 

1. Ps=Pbar+(Pg/13"6) •,•o•O• )+ "==',2.• /13.6): 

2. Pm= P,,r *(•H/13.6) 2 •.•7 + 2-•? /13.6) 

3. V•=17.•*V•*Y*(P•) 17.64"(•.• )*( .• 

4a. V•c(•) 0.04706 W,•p 0.04706*( •l• )= 

4b. V•s•(=,) 0.04715 W,• 0.04715*( t$, 

e.,=V.,,,Z(Vm,,,+ V.,,,) 5.3 9 Y( 5e. 5 

For saturated sources (No. 6 8 only): 

6. TBw•= (106"37"{28271('m*365)}/Ps 10637"{2827/( .364,8))/( 

7. TVwst,•= Vmstd*( TB•/1- TBws) )*( )/( 1 

8. TVIc= TVwstJ0.04707 / 

Md 0.44(%CO2)+0.32(%O2)+0.28((100-(%CO2+%O2)) 

0.44( :• )*0.32( |'i'.• )+0.28(100-( • * 

10. M•=Md(1-Bws)+18B•s= ( •-I• )*(1- .•/4 )+18( 

11. V,= 85.49 C•* q•P • •s / (Ms* Ps)] 

12. Q•=V•*A•*60 31,•] )( I•.• )(60)= 

13. 

14. 

Qs Qa* (528/Ts)*(PJ29.92) ( 5(35•4• )*(528/ "•. 5 )*( Zl•.•5.,• /29.92) =.Zl3•} 

Q=•= Q, (1- Bws) (528•,)*(P•29.92) =( • )(1- {•4 )*(528/7G•.• )*(•.•/29.92) 

C•=0.01543*(M•Vm•) 0.01543*( {,• / •0• )= •.• • 

17. E/Btu= (Cs/7000)*{(Fd*20.9)/(20.9-%O2)} 

/7000)*{( )'20.9)/(20.9-( )} 

18. %EA= 100%* {(%O2)-0.5*(%CO)} / (0.264(%N2) (%02)+ 0.5*(%CO)} 10•%*{( )-0.5( )} / {0.264( )-( 

21 .•PM 

22. Vn=Ts/P,*{(0.002669) V•c + (V•n Y Pm)/Tm)} ('•. • /•,t•5,} )*{(0.002669)( •2.• )+( -•o(•l• )( oO• 

23. C,=0.01543" (Mn/Vn) 0.01543"( / •4.t• 

24. I=Vnl00/(60*e*V,*A,) = •4,.111:• )100/(60)( (m•)( •lo•'• 

)+o.5( 

)*(6o/7ooo) 

)=