Name:

Title:

Company:

Sign Date:

Name: Mike Taylor

Title: President

Company: Catalyst Air Management

Sign Date:

Permitted Facility Representative / Date Testing Company Representative / Date

KY6041 Spurlock Unit 1

Final Test Report 

for

/ /

Based on information and belief formed 

after reasonable inquiry, I certify that the 

statements and information in this test 

report are true, accurate, and complete.

I have reviewed all testing details and 

results in this test report and hereby 

certify that the test report is authentic 

and accurate.

Monday, February 21, 2011 Page 1 of 10
KY6041 Spurlock Unit 1

Facility Information:

Spurlock

1301 West 2nd st.

Maysville KY 41056

Contact: Louis Petrey

Phone: 859-745-4157 ext. 204

Fax:

Email: louis.petrey@ekpc.coop

Testing Company:

Catalyst Air Management

2505 Byington-Solway Rd

Knoxville TN 37931

Contact:Mike Taylor

Phone: 865-531-0075

Fax: 831-531-0750

Email: mike.taylor@catalystair.com

Air Permit Number:

6041

Permitted Source ID/Name:

1 Hugh L. Spurlock Generating Station

Permitted Maximum Process Rate:

3500 mmBtu/hr

Max. Normal Operation Process Rate: Target Process Test Rate

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

 process flow diagram:

Industry/SCC/NAIS 221112

Sampling Location Information:

Test Parameter Information:

AFS #: 110017429521 FRS #: 110017429521

SCC / Description 10100202 External Combustion Boilers - Electric Generation - Bituminous/Subbituminous 

Coal - Pulverized Coal: Dry Bottom (Bituminous Coal) 

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

Location

Round

Duct

Diam.

Distance from 

upstream dist.

Distance from

downstream dist.

Number of

Traverse Ports

Equiv. 

Diam

Min.Travers 

Points

Rect. Duct 

Length /Width

KY6041 

Spulock Unit 1

252 0 0 0 2479.2 3600 4 20

Target

Parameter 

Test

Method

Number of

Test Runs

Test Run

Duration

Sample 

Location Points Comments

KY6041 Arsenic Method 29 3 240 0

Spulock Unit 1

KY6041 Antimony Method 29 3 240 0

Spulock Unit 1

KY6041 Beryllium Method 29 3 240 0

Spulock Unit 1

Monday, February 21, 2011 Page 2 of 10
KY6041 Spurlock Unit 1

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

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

of request AND approval, including dates.

KY6041 Cadmium Method 29 3 240 0

Spulock Unit 1

KY6041 Chromium Method 29 3 240 0

Spulock Unit 1

KY6041 Cobalt Method 29 3 240 0

Spulock Unit 1

KY6041 Lead Method 29 3 240 0

Spulock Unit 1

KY6041 Manganese Method 29 3 240 0

Spulock Unit 1

KY6041 Nickel Method 29 3 240 0

Spulock Unit 1

KY6041 Selenium Method 29 3 240 0

Spulock Unit 1

Inorganic (Aqueous) 

Condensible Part.

KY6041 Method 5/OTM-28 3 240 0

Spulock Unit 1

KY6041 Filterable Particulate Method 5/OTM-28 3 240 0

Spulock Unit 1

KY6041 Total Particulate Method 5/OTM-28 3 240 0

Spulock Unit 1

Organic Condensible 

Particulate

KY6041 Method 5/OTM-28 3 240 0

Spulock Unit 1

Monday, February 21, 2011 Page 3 of 10
KY6041 Spurlock Unit 1

Sampling / Stack Data Results Summary

Location KY6041 Spulock Unit 1 - Method 29

Average

Run Number M29-1 M29-2 M29-3

Test Date 5/4/2010 5/4/2010 5/5/2010

Run Start Time 6:12:00 AM 11:17:00 

AM

5:39:00 AM

Run Finish Time 10:25:00 AM 3:32:00 PM 9:50:00 AM

Net Run Time, minutes 240 240 240

Dry Gas Meter Volume Sampled, dscf 117.424 117.115 120.552 118.364

Moisture Content of Stack Gas, % 15.24 12.24 15.19 14.223

Moisture Saturation at Stack Gas Temperature, % 15.58 15.52 15.25 15.450

Carbon Dioxide, % 10.4 10.3 10.2 10.300

Oxygen, % 8.4 8.6 8.7 8.567

Average Stack Gas Temperature, °F 129.95 129.80 129.25 129.667

Dry Volumetric Flow Rate, dry scfm 674,368.7 693,043.7 683,646.4 683,686.267

Actual Wet Volumetric Flue Gas Flow Rate, acfm 918,757.2 911,691.4 926,862.0 919,103.533

Percent Isokinetic of Sampling Rate, % 99.7 96.7 100.9 99.100

F-Factor, dscfm/MMBtu @ %O2 9780 9780 9780 9,780.000

Fw 10640 10640 10640 10,640.000

Fc 1800 1800 1800 1,800.000

Monday, February 21, 2011 Page 4 of 10
KY6041 Spurlock Unit 1

Location KY6041 Spulock Unit 1 - Method 5/OTM-28

Average

Run Number

Test Date

Run Start Time

Run Finish Time

Net Run Time, minutes

Dry Gas Meter Volume Sampled, dscf

Moisture Content of Stack Gas, %

Moisture Saturation at Stack Gas Temperature, %

Carbon Dioxide, %

Oxygen, %

Average Stack Gas Temperature, °F

Dry Volumetric Flow Rate, dry scfm

Actual Wet Volumetric Flue Gas Flow Rate, acfm

Percent Isokinetic of Sampling Rate, %

F-Factor, dscfm/MMBtu @ %O2

Fw

Fc

Monday, February 21, 2011 Page 5 of 10
KY6041 Spurlock Unit 1

Emissions Summary

Location: KY6041 Spulock Unit 1 - Method 29

Compound: Antimony

Average

RunNumber M29-1 M29-2 M29-3

Mass_mg 0.0012 0.0012 0.0012 0.001

lb/mmBtuO2 3.68E-07 3.75E-07 3.68E-07 0.000

Compound: Arsenic

Average

RunNumber M29-1 M29-2 M29-3

Mass_mg 0.00145 0.00207 0.0012 0.002

lb/mmBtuO2 4.45E-07 6.48E-07 3.68E-07 0.000

Compound: Beryllium

Average

RunNumber M29-1 M29-2 M29-3

Mass_mg 0.0003 0.0003 0.0003 0.000

lb/mmBtuO2 9.21E-08 9.38E-08 9.19E-08 0.000

Compound: Cadmium

Average

RunNumber M29-1 M29-2 M29-3

Mass_mg 0.00043 0.0003 0.0003 0.000

lb/mmBtuO2 1.32E-07 9.38E-08 9.19E-08 0.000

Compound: Chromium

Average

RunNumber M29-1 M29-2 M29-3

Mass_mg 0.01355 0.01205 0.01101 0.012

lb/mmBtuO2 4.16E-06 3.77E-06 3.37E-06 0.000

Compound: Cobalt

Average

RunNumber M29-1 M29-2 M29-3

Mass_mg 0.0012 0.00107 0.00044 0.001

lb/mmBtuO2 3.68E-07 3.35E-07 1.35E-07 0.000

Compound: Lead

Average

RunNumber M29-1 M29-2 M29-3

Mass_mg 0.01688 0.00856 0.00711 0.011

lb/mmBtuO2 5.18E-06 2.68E-06 2.18E-06 0.000

Compound: Manganese

Average

RunNumber M29-1 M29-2 M29-3

Mass_mg 0.00948 0.00881 0.0077 0.009

lb/mmBtuO2 2.91E-06 2.76E-06 2.36E-06 0.000

Compound: Nickel

Average

Monday, February 21, 2011 Page 6 of 10
KY6041 Spurlock Unit 1

Process Run Data

RunNumber M29-1 M29-2 M29-3

Mass_mg 0.01307 0.00839 0.01974 0.014

lb/mmBtuO2 4.01E-06 2.62E-06 6.05E-06 0.000

Compound: Selenium

Average

RunNumber M29-1 M29-2 M29-3

Mass_mg 0.0669 0.0176 0.0259 0.037

lb/mmBtuO2 2.05E-05 5.51E-06 7.94E-06 0.000

Location: KY6041 Spulock Unit 1 - Method 5/OTM-28

Compound: Filterable Particulate

Average

RunNumber M5-28-1 M5-28-2 M5-28-3

Mass_mg 19.9 12.6 12.9 15.133

lb/mmBtuO2 4.76E-03 3.11E-03 3.18E-03 0.004

Compound: Inorganic (Aqueous) Condensible Pa

Average

RunNumber M5-28-1 M5-28-2 M5-28-3

Mass_mg 34 32 34 33.333

lb/mmBtuO2 8.13E-03 7.90E-03 8.39E-03 0.008

Compound: Organic Condensible Particulate

Average

RunNumber M5-28-1 M5-28-2 M5-28-3

Mass_mg 1 1.3 1.4 1.233

lb/mmBtuO2 2.39E-04 3.21E-04 3.45E-04 0.000

Compound: Total Particulate

Average

RunNumber M5-28-1 M5-28-2 M5-28-3

Mass_mg 54.9 45.9 48.3 49.700

lb/mmBtuO2 1.31E-02 1.13E-02 1.19E-02 0.012

Monday, February 21, 2011 Page 7 of 10
KY6041 Spurlock Unit 1

Process Run Data

APCD Run Data

Process Lab Run Data

Run Name Value UOM Comments

Target

Value

1 Heat Input Million Btus/million BTU using O2 2920.5 0

2 Heat Input Million Btus/million BTU using O2 2942 0

3 Heat Input Million Btus/million BTU using O2 2957.8 0

1 Unit Load 293 MW 0

2 Unit Load 293 MW 0

3 Unit Load 293 MW 0

1 Steam Rate 2122.3 1000 lbs/hr 0

2 Steam Rate 2169.9 1000 lbs/hr 0

3 Steam Rate 2195.6 1000 lbs/hr 0

Run Name Value UOM Comments

Target

Value

1 LOW NOX BURNERS 0 0

4 LOW NOX BURNERS 0 0

5 LOW NOX BURNERS 0 0

1 ELECTROSTATIC PRECIPITATOR 0 Volts 0

4 ELECTROSTATIC PRECIPITATOR 0 Volts 0

5 ELECTROSTATIC PRECIPITATOR 0 Volts 0

1 SCR (SELECTIVE CATALYTIC REDUCTION) 398.11 lb/hr 0

4 SCR (SELECTIVE CATALYTIC REDUCTION) 377.03 lb/hr 0

5 SCR (SELECTIVE CATALYTIC REDUCTION) 386.83 lb/hr 0

1 WET SCRUBBER 147.97 GPM 0

4 WET SCRUBBER 213.39 GPM 0

5 WET SCRUBBER 186.43 GPM 0

1 WET ELECTROSTATIC PRECIPITATOR 0 Volts 0

4 WET ELECTROSTATIC PRECIPITATOR 0 Volts 0

5 WET ELECTROSTATIC PRECIPITATOR 0 Volts 0

Run Name Value UOM Comments

1 0

Monday, February 21, 2011 Page 8 of 10
KY6041 Spurlock Unit 1

Sampling / Stack Data Results Detail

Location KY6041 Spulock Unit 1 - Method 29

Average

Run Number M29-1 M29-2 M29-3

Test Date 5/4/2010 5/4/2010 5/5/2010

Run Start Time 6:12:00 AM 11:17:00 AM 5:39:00 AM

Run Finish Time 10:25:00 AM 3:32:00 PM 9:50:00 AM

Net Traversing Points 20 20 20

Net Run Time, minutes 240 240 240

Nozzle Diameter, inches 0.215 0.215 0.215 0.215

Pitot Tube Coefficient 0.84 0.84 0.84 0.840

Dry Gas Meter Calibration Factor 1 1 1 1.000

Barometric Pressure, inches of Mercury 29.01 29.01 29.1 29.040

Average Orifice Meter Differential, inches H2O 0.84 0.85 0.87 0.853

Dry Gas Meter Volume Sampled, cubic feet 123.180 124.102 125.563 124.282

Average Dry Gas Meter Temperature, °F 78.18 83.65 76.05 79.293

Dry Gas Meter Volume Sampled, dscf 117.424 117.115 120.552 118.364

Total Moisture Liquid collected, g 448.6 347.1 458.6 418.100

Volume of Water Vapor, standard cubic feet 21.12 16.34 21.59 19.683

Moisture Content of Stack Gas, % 15.24 12.24 15.19 14.223

Moisture Saturation at Stack Gas Temperature, % 15.58 15.52 15.25 15.450

Dry Mole Fraction 0.8476 0.8776 0.8481 0.858

Carbon Dioxide, % 10.4 10.3 10.2 10.300

Oxygen, % 8.4 8.6 8.7 8.567

Carbon Monoxide & Nitrogen, % 81.2 81.1 81.1 81.133

Fuel Factor 1.20 1.19 1.20

Dry Molecular Weight, lb/lb-Mole 30.00 29.99 29.98 29.990

Wet Molecular weight, lb/lb-Mole 28.17 28.52 28.16 28.283

Flue Gas Static Pressure, inches of H2O -0.75 -0.75 -0.75 -0.750

Absolute Flue Gas Pressure, inches of Mercury 28.95 28.95 29.04 28.980

Average Stack Gas Temperature, °F 129.95 129.80 129.25 129.667

Average Velocity Head, inches of H2O 0.5239605235

76026

0.522409933

269197

0.535407900

093508

0.527

Average Stack Gas Velocity, feet/second 44.21 43.87 44.60 44.227

Stack Cross-Sectional Area, square feet 346.361 346.361 346.361 346.361

Dry Volumetric Flow Rate, dry scfm 674,368.7 693,043.7 683,646.4 683,686.267

Actual Wet Volumetric Flue Gas Flow Rate, acfm 918,757.2 911,691.4 926,862.0 919,103.533

Percent Isokinetic of Sampling Rate, % 99.7 96.7 100.9 99.100

Percent Excess Air, % 64.4 67.1 68.4 66.633

F-Factor, dscfm/MMBtu @ %O2 9780 9780 9780 9,780.000

Round Duct Diameter, inches 252 252 252

Rectangular Duct Width, inches 0 0 0

Rectangular Duct Length, inches 0 0 0

Fw 10640 10640 10640 10,640.000

Fc 1800 1800 1800 1,800.000

Monday, February 21, 2011 Page 9 of 10
KY6041 Spurlock Unit 1

Location KY6041 Spulock Unit 1 - Method 5/OTM-28

Average

Run Number

Test Date

Run Start Time

Run Finish Time

Net Traversing Points

Net Run Time, minutes

Nozzle Diameter, inches

Pitot Tube Coefficient

Dry Gas Meter Calibration Factor

Barometric Pressure, inches of Mercury

Average Orifice Meter Differential, inches H2O

Dry Gas Meter Volume Sampled, cubic feet

Average Dry Gas Meter Temperature, °F

Dry Gas Meter Volume Sampled, dscf

Total Moisture Liquid collected, g

Volume of Water Vapor, standard cubic feet

Moisture Content of Stack Gas, %

Moisture Saturation at Stack Gas Temperature, %

Dry Mole Fraction

Carbon Dioxide, %

Oxygen, %

Carbon Monoxide & Nitrogen, %

Fuel Factor

Dry Molecular Weight, lb/lb-Mole

Wet Molecular weight, lb/lb-Mole

Flue Gas Static Pressure, inches of H2O

Absolute Flue Gas Pressure, inches of Mercury

Average Stack Gas Temperature, °F

Average Velocity Head, inches of H2O

Average Stack Gas Velocity, feet/second

Stack Cross-Sectional Area, square feet

Dry Volumetric Flow Rate, dry scfm

Actual Wet Volumetric Flue Gas Flow Rate, acfm

Percent Isokinetic of Sampling Rate, %

Percent Excess Air, %

F-Factor, dscfm/MMBtu @ %O2

Round Duct Diameter, inches

Rectangular Duct Width, inches

Rectangular Duct Length, inches

Fw

Fc

Monday, February 21, 2011 Page 10 of 10