PARTICULATE/HF/HC1 EMISSIONS TESTING 

ON THE 

SCRUBBER/BAGHOUSE EXHAUST 

OF 

TUNNEL IGLN #1 

BORAL BRICKS, INC. 

AUGUSTA PLANT 4 

1630 ARTHERN ROAD 

Augusta(Richmond County), Georgia 30901 

Project # 02131 

October 16-17, 2002 

Testing conducted for: 

Mr. David Johnson 

Environmental Manager 

Boral Bricks, Inc. 

PO Box 1178 

Columbus, Georgia 31902 

(334) 480-2487 

ANALYTICAL TESTING CONSULTANTS, INC. 

301 Brookdale Street 

/, Kannapolis, N. C. 28083 

/ (704) 932-3193 phone 

(800) 733-3193 toll-free 

(704) 932-0570 fax 

corp @atc-net.net e-mail 

www.atc-net.net Web page 

Distribution: 

Mr. David Johnson 

(Five copies) 

Issue Date: 

November 14, 2002 
TABLE OF CONTENTS 

Page 

Number 

Introduction .......................................... 3 

Certification of Results ........................... 3 

Source Description ..................................... 4 

Results and Process Summary ............................ 5 

Results, Conclusions and Comments 8 

Sampling and Analytical Procedures 10 

References .......................................... 11 

Test ONE Isokinetic Data and Calculations 

Emission Rate Calculations 13 

Isokinetic Data and Calculations 16 

Moisture Data 

................................. 19 

Isokinetic Sampling Rate Calculation 20 

Test TWO Isokinetic Data and Calculations 

Emission Rate Calculations 21 

Isokinetic Data and Calculations 24 

Moisture Data 

.................................. 27 

Isokinetic Sampling Rate Calculation 28 

Sample Calculations ................................... 29 

Nomenclature .............. 31 

Calculation Formulae 33 

Appendix I ............... 36 

Sampling Data Sheets 37 

Stack Sketches 50 

Enthalpy Analytical, Inc. Lab Report 53 

Analytical Testing Consultants, Inc. Lab Report 125 

LELAP Certification ..................... 139 

Process Data 

.................................. 150 

Calibration Data 172 

Page 2 of 202 
INTRODUCTION 

This report presents the results of particulate/hydrogen fluoride/hydrogen chloride emissions 

testing conducted on the scrubber/baghouse exhaust of the Plant 4 #1 Tunnel Kiln. Emissions 

testing via US EPA methods 5/26a was performed by Analytical Testing Consultants, Inc. of 

Kannapolis, NC. The two man test team consisted of Dan McCombs and Kevin Adkins. 

Testing was completed on Wednesday and Thursday, October 16-17, 2002. Ms. DeAnna Oser of 

the Georgia Department of Natural Resources witnessed portions of the sampling. Mr. David 

Johnson of Boral Bricks was on site during sampling and was responsible for collection of 

process data. Two separate tests of three one-hour runs were conducted each day changing the 

operation parameters of the dry lime scrubber and the pressure drop across the baghouse. 

Executive Summary 

Both tests showed the HF and HC1 emissions were well below levels contained in facility Part 70 

operating permit (3251-245-0009-V-01-5) of 2.25 lbs per hour. Runs 1,2,3 averaged 0,,D,I'• o. 

lbs/hr particulate, <0.046 lbg/hr HF and 0.079 lbs/hr HC1. Runs 4,5,6 average were 0.372 lbs/hr 

particulate, <0.007 lbs/hr HF and 0.038 Ibs/hr HC1. Allowable particulate emissions/are based 

upon total quantltaes from : .r •,,,,,•: •,•,• 1o, an,• the Tunnel 

Kiln #1 [Rule 391-3-1-.02(2)(e)]. The kiln average 9.18 tons per hour on October 16 th and 8.26 

tons per hour on October 17 th. 

CERTIFICATION OF RESULTS 

"By out" signature we certify that the testing and the reporting of the test results contained herein are prepared to 

the best of our abilities and that, to our knowledge, the data have been calculated and reported correctly. No data 

or information has knowingly been omitted." 

W. Keith Poole 

Laboratory Manager/Technical Director 

C. Daniel McCornbs 

Quality Manager/Team Leader 

Page 3 of 202 
PROCESS DESCRIPTION 

Belt conveyors transport prepared clay form the Processed Clay Storage Building bays to Plant 4 

[i.e. via the Clay Feed System Conveyors (P4) (ID CB401)]. The materials are conveyed to Plant 

4 where they feed the Plant 4 brick forming line. The forming line starts with a surge bin (ID 

SB401) which feeds two (2) pug mills in series. Water may be added at the pug mills depending 

on the moisture content of the clay. The "pugged" clay then enters an extruder and is formed as a 

column of brick. The column of brick may or may not be sand coated and textured (SC 401), 

though typically not. Once the column is coated/textured, it is then cut into green bricks. 

Green brick are stacked onto kiln cars by a setting machine and are placed in a holding area 

where the moisture content is lowered slightly. The kiln cars exit theholding area directly into a 

set of Tunnel dryers for primary drying. The dryers are heated with waste heat from the cooling 

sections of the kiln. A pressure differential is maintained within the kiln to prevent hot air and 

pollutants from entering the kiln cooling section. Therefore, pollutant emissions from the dryer 

stacks are negligible. 

Finally, dried brick are moved directly from the dryers into Tunnel Kiln #1 (EU401) [Tunnel 

Kiln #2 (EU402) is a proposed future kiln]. The tunnel kiln is fueled by natural gas with propane 

as a backup fuel. Final evaporation of free water, dehydration, oxidation, vitrification, flashing, 

and cooling of bricks occurs in the kiln. Emissions from the kiln are routed through a single 

control device. The control equipment (CE401) serves to reduce HF and HC1 emissions from the 

kiln. Brick exiting the kiln are packaged and moved to outside storage prior to distribution. 

The tunnel kiln control device-CE401-is a Hydrated lime Powdered Injection Scrubber (w/ 

Venturi Reactor). This serves to reduce the emissions of HF and HC1 in the airstream prior to 

release to atmosphere through the single 59.25' round, vertical stack} 

IProcess description provided by 

Environmental Manager, Boral Bricks, Inc. 

David Johnson, 

Page 4 of 202 
RESULTS SUMMARY 

SYSTEM Boral Bricks 

Tunnel Kiln #1 

TEST DATE 10/16/02 

PARAMETER Run #1 Run #2 Run #3 

GENERAL 

QS, FLOW, ACFM 51629 49929 50539 

Q STD DRY, FLOWSCFM 38592 37141 37513 

Vm STD (ft3) 42.94 40.48 40.93 

%1 104.23 102.10 102.21 

PARTICULATE EMISSIONS 

PMRc (Ibs/hr) 0.083 

Cs (GR/SCFD) 0.0003 

HYDROGEN FLUORIDE EMISSIONR 

PMRc (Ibs/hr) <0.008 

ALLOWABLE (Ibs/hr) 

HYDROGEN CHLORIDE EMISSIONR 

PMRc (Ibs/hr) 0.127 

ALLOWABLE (Ibs/hr) 

0.194 

0.0006 

0.065 

0.04 

0.303 

0.0009 

0.064 

0.08 

AVERAGE 

50699 

37749 

0.194 

0.0006 

<0.046 

2.25 

0.079 

2.25 

Page 5 of 202 
Boral Bricks, Augusta Plant 4 Operating Conditions during Stack Test 

October 16 17, 2002 

Provided by Boral Bricks Inc. 

Kiln (EU401) Operatin.q Conditions' 

DATE 

10/16/02 

PUSH RATE 

(CPD)* 

2O 

BRICKS PER 

CAR 

4368 

10/17/02 18** 4368 8.26 

THROUGHPUT 

(TPH)* :--_• 

9.18 

Product in kilns: Standard size Savannah Brown (10-670 flashed) pavers 

Average fired brick weight: 5.044 fbs.* 

CPD Kiln Cars per Day, TPH Tons per Hour.. 

Plant was unable to achieve the manufacturing level necessary to maintain the 20 cpd push for both days. 

***Based on 5 brick samples weighing. 5.05, 5.03, 5.06, 5.04, and 5.04 Ibs each 

Control Device (CE401) Operatinq Conditions: 

Two separate performance tests were conducted under separate control device operating 

conditions in order to confirm the operating ranges that demonstrate compliance. The first test 

(Runs 1-3) was conducted at a low reagent feed rate while maintaining a mid to low pressure 

drop across the baghouse. The second test (Runs 4-6) was conducted at a slightly higher 

reagent feed rate and an even lower pressure drop. Two additional engineering tests were 

conducted on October 17 •h and the results of those tests will be provided under separate cover. 

The below table provides ranges* of control device operating conditions that were recorded 

during the two tests. The two performance test scenarios are as follows: 

TEST 

2 

RUN #S DATE 

1-3 10/16 15:35-19:35 

4-6 10/17 09:40-13:57 

TIME LIME FEED RATE*** 

PERIOD** (LB/15-MIN) 

2.0-3.9 

4.6 -6.9 

PRESSURE LOSS 

(INCHES H20) 

2.04 3.08 

1.64 2.33 

Ranges only see attached CEM printouts for complete monitoring data 

Test times. CEM times are approx. 6 minutes faster than times reflected in stack test report. 

Fresh lime feed rate Total time feed rate (i. e. no recycled lime used) 

Page 7 of 202 
RESULTS, CONCLUSIONS AND COMMENTS 

A summary of some pertinent results appear in the preceding RESULTS SUMMARY. For 

additional information please consult the CALCULATIONS and DATA SHEETS sections of 

this report. 

Test ONE Runs 1,2,3 

Stack velocity, as determined by US EPA method 2, was calculated based upon the differential 

pressure measurement of the impact and static sides of a Stauschiebe type pitot tube at twelve 

different points in each of the two test ports. The resultant mean stack velocity of 44.13 feet per 

second fit/s) was multiplied times the stack area of the test plane (19.15 ft •-) and by 60 (time 

conversion) to achieve a mean actual volumetric flow rate of 46,189 cubic feet per minute 

(acfm). Prior to calculation of the emission rates, the ACFM value from each individual run was 

adjusted to standard conditions. The mean standard volumetric flow rate was 37,749 scfm. 

Particulate emissions were calculated utilizing the combined net weights of the filter catch and 

the residue from the front half rinse (nozzle, probe, cyclone bypass, and front half of filter 

assembly) and averaged 0.046 pounds per hour (lbs/hr) with a concentration of 1.00e -°4 grains 

per dry standard cubic foot (gr/scfd). There is no individual, associated particulate allowable 

for this source. 

Hydrogen Fluoride concentrations were not detected in the #1 test run. Emissions of< 0.046 

lbs/hr were calculated using the detection limit for run one and the values for runs two and three. 

This less than average is significantly less than the allowable of 2.25 lbs/hr. 

Hydrogen Chloride concentrations were detected at a level between the minimum detection limit 

and the limit of quantization and averaged 0.079 lbs/hr. HC1 emissions from the #1 Tunnel Kiln 

and #2 Tunnel Kiln (yet to be installed) are required to be no more than 2.25 lbs/hr. 

Test TWO Runs 4,5,6 

Stack velocity, as determined by US EPA method 2, was calculated based upon the differential 

pressure measurement of the impact and static sides of a Stauschiebe type pitot tube at twelve 

different points in each of the two test ports. The resultant mean stack velocity of 42.04 feet per 

second fit/s) was multiplied times the stack area of the test plane (19.15 ft •-) and by 60 (time 

conversion) to achieve a mean actual volumetric flow rate of 48,300 cubic feet per minute 

(acfm). Prior to calculation of the emission rates, the ACFM value from each individual run was 

adjusted to standard conditions. The mean standard volumetric flow rate was 36,651 scfm. 

Particulate emissions were calculated utilizing the combined net weights of the filter catch and 

Page 8 of 202 
the residue from the front half rinse (nozzle, probe, cyclone bypass, and front half of filter 

assembly) and averaged 0.038 pounds per hour (lbs/hr) with a concentration of 1.20e .°4 grains 

per dry standard cubic foot (gr/scfd). There is no individual, associated particulate allowable 

for this source. 

Hydrogen Fluoride concentrations were not detected in any of the test runs, field blank, or 

reagent blanks. Emissions of <0.007 lbs/hr were calculated at the detection limit for each run, 

significantly less than the allowable of 2.25 lbs/hr. 

Hydrogen Chloride concentrations were detected at a level between the minimum detection limit 

and the limit of quantization and averaged 0.038 lbs/hr. HC1 emissions from the #1 Tunnel Kiln 

and #2 Tunnel Kiln (yet to be installed) are required to be no more than 2.25 lbs/hr. 

Ms. DeAnna Oser of the State of Georgia Department of Natural.Resources requested internal 

QA procedures due to the very low reported results from previous testing. A detailed description of a Blind spike and a second Source Standard performed for this request are reported in the 

Enthalpy Analytical Narrative Summary. The Blind spike had a calculated percent recovery of 

98.2%. The Second Source standard exhibited a 97.1% tag value for HF and 98.1% tag value for 

HC1. 

Page 9 of 202 
SAMPLING AND ANALYTICAL PROCEDURES 

Particulate/HC1/HF emissions testing and analysis were performed according to procedures developed by the U. S. Environmental Protection Agency (USEPA) and referred to as Method 

5/26A. Sampling port locations and number of test points to be used were determined according to Method 1 and are shown in the data sheets section of this report. The above federal test 

methods appear in the Code of Federal Regulations (Reference 1). 

Test point locations and sampling port placement for velocity traverses are shown in the data 

sheets. Test point locations were calculated based upon a 59.25" diameter, round stack with 2 

four inch test ports located ninety degrees apart. 

Twelve points were sampled in each test port. An all glass US EPA method 5/26a sampling train 

was utilized that employed glass nozzles and probe liners. A glass filter assembly held a Teflon 

filter frit with Teflon filter for determination of particulate emissions. Connections to the 

condenser train was a glass "double el" with a thermocouple well for measurement of exhaust 

temperature of the filter. The condenser train consisted of five glass impingers connected 

sequentially. The first and second impingers were charged with 100 ml 0.1 N H2SO4, the third 

and fourth with 100 ml of 0.1 N H•_SO 4. The fifth impinger contained 300g of silica gel. All 

sample recovery was conducted on-site by Dan McCombs and Kevin Adkins. Condenser train 

collections were measured and rinsed into pre-labeled amber glass jars. The sulfuric acid 

fractions were forwarded t0 Enthalpy Analytical, Inc. a LELAP accredited laboratory (Certificate 

No. 04010, agency interest no. 85848). A copy of Enthalpy's accreditation is included in 

Appendix I. for determinations of HCI,q-IF via US EPA 26a. The sodium hydroxide fractions 

were discarded. 

The front half of the sampling train was rinsed with reagent grade acetone and stored in 500 ml 

Nalgene® bottles and transported to ATC for analysis. Liquid levels were marked on the 

sampling bottles with a marker. Particulate analysis was completed Analytical Testing 

Consultants, Inc., a LELAP accredited laboratory (Certificate No. 04044) 

A blank of the acetone reagent was collected in the field, along with the field samples and 

analyzed side by side. According to standard practices and the QA/QC handbook EPA-600/4-94- 

038c, acetone blanks should not be subtracted over 0.001%. The acetone residue of 0.0004 was 

well under the maimum allowable residue of 0.0008. Corrections are show in the particulate lab 

report. 

Page 10 of 202 
•FERENCES 

I. CODE OF •DER• REGULATIONS, Title 40, Part 60; Appendix A,. July 1, 2001. 

Page t 1 of 202 
ISOKINETIC DATA AND CALCULATIONS 

TEST ONE 

Emission Rate Calculations 

Particulate 

HC1 

HF 

Isokinetic Data and Calculation 

Moisture Data 

Isokinetic Sampling Rate Data 

TEST TWO 

Emission Rate Calculations 

Particulate 

HC1 

HF 

Isokinetic Data and Calculation 

Moisture Data 

Isokinetic Sampling Rate Data 

Sample Calculations 

Nomenclature 

Calculation Formulae 

Page 12 of 202 
PARTICULATE EMISSION RATE CALCULATION 

LOCATION: Boral Bricks 

SOURCE: Tunnel Kiln #1 

DATA 

DATE 

RUN TIME (min) 

Dn (in) 

An (ft2) 

A VG DH (in H20) 

P A TM (in Hg) 

Pm (in Hg) 

Ps (GAUGE) 

Ps (IN HG) 

Tm (F) 

Tm (R) 

Vm (ft3) 

Vm STD (ft3) 

VLQ (ml) 

VV STD (ft3) 

V STD (ft3) 

%M 

MD 

MWD 

M 

Ts(F) 

Ts(R) 

SUM SQRT DP 

N DP 

A VG SQRT DP 

CP 

Vs (ft/s) 

Ds (in) 

As (ft2) 

QS, FLOW, ACFM 

Q STD (ft3/min) 

Q STD DRY, FLOW SCFM 

WT (gm) 

%1 

%C02 

%02 

%C0 

%N2 

PMRc (Ibs/hr) 

Cs (GR/SCFD) 

Run #1 Run #2 Run #3 AVERAGE 

10/16/02 10/16/02 10/16/02 

60.00 60.00 60.00 

0.250 0.250 0.250 

3.41E-04 3.41E-04 3.41E-04 

1,68 1.54 1.56 

29.55 29.55 29.55 

29.67 29.66 29.67 

-0.54 -0.54 -0.54 

29.51 29.51 29.51 

94.38 87.31 81.60 

554.05 546.98 541.27 

43.94 40.91 40.93 

42.94 40.48 40.93 

43.00 44.00 44.60 

2.03 2.07 2.10 

44.97 42.56 43.03 

,4.51 ,4.87 4.88 4.76 

0.955 0.951 0.951 

28.94 28.94 28,93 

28.44 28.40 28.40 

,205.63 ,206.29 207.67 206.53 

665.30 665.96 667.34 666.20 

16.87 16.30 16.48 

24.00 24.00 24.00 

0.70 0.68 0.69 

0.84 0,84 0.84 

44.94 43,46 43.99 44.13 

59.25 59,25 59.25 

19.15 19.15 19.15 

51629 -49929 ,50539 50699 

,40413 39044 39439 39632 

,38592 37141 ,37513 37749 

0.0007 0.0016 0.0025 

104.23 102.10 102.21 

1.00 1.00 1.00 1.00 

.19.41 ,19.39 ,19.37 19.39 

0.00 0.00 0.00 

79.59 79.61 79.63 

0.083 0.194 0.303 0.194 

0.0003 0.0006 0.0009 0.0006 

Page 13 of 202 
HCI EMISSION RATE CALCULATION 

LOCATION: Boral Bricks 

SOURCE: Tunnel Kiln #1 

DATA Run #1 Run #2 Run #3 AVERAGE 

DATE 10/16/02 10/16/02 10/16/02 

RUN TIME (rain) 60.00 60.00 60.00 

Dn (in) 0,250 0.250 0.250 

An (ft2) 3.41E-04 3.41E-04 3.41 E-04 

A VG DH (in H20) 1.68 1.54 1.56 

P A TM (in Hg) 29.55 29.55 29.55 

Pm (in Hg) 29.67 29.66 29.67 

Ps (GAUGE) -0.54 -0.54 -0.54 

Ps (IN HG) 29.51 29.51 29.51 

Tm (F) 94.38 87.31 81.60 

Tm (R) 554.05 546.98 541.27 

Vm (ft3) 43,94 40.91 40.93 

Vm STD (ft3) 42.94 40.48 40.93 

VLQ (ml) 43.00 44.00 44.60 

VV STD (ft3) 2.03 2.07 2.10 

V STD (ft3) 44.97 42.56 43.03 

%M 4.51 4.87 4.88 4.76 

MD 0.955 0.951 0.951 

MWD 28.94 28.94 28.93 

M 28.44 28.40 28.40 

Ts (F) 205.63 206.29 207.67 206.53 

Ts (R) 665.30 665.96 667,34 666.20 

SUM SQRT DP 16.87 16.30 16.48 

N DP 24.00 24.00 24.00 

A VG SQRT DP 0.70 0.68 0,69 

CP 0.84 0.84 0.84 

Vs (ft/s) 44.94 43.46 43.99 44.13 

Ds (in) 59.25 59.25 59.25 

As(ft2) 19.15 19.15 19.15 

QS, FLOW, ACFM 51629 49929 50539 50699 

Q STD (ft3/min) 40413 39044 39439 39632 

Q STD DRY, FLOWSCFM 38592 37141 37513 37749 

WT (gm) 1.0660 E-03 2.8900E-04 6.2100E-04 

%1 104.23 102.10 102.21 

%C02 1.00 1.00 1.00 1.00 

%02 19.41 19.39 19.37 19.39 

%C0 0.00 0.00 0.00 

%N2 79.59 79.61 79.63 

PMRc(Ibs/hr) ,0.127 ,0.035 0.075 0.079 

Cs (GR/SCFD) 0.0004 0.0001 0.0002 0.0002 

Page 14 of 202 
HF EMISSION RATE CALCULATION 

LOCATION: Boral Bricks 

SOURCE: Tunnel Kiln #1 

DATA Run #1 Run #2 Run #3 AVERAGE 

DATE 10/16/02 10/16/02 10/16/02 

RUN TIME (rain) 60.00 60.00 60.00 

Dn (in) 0.250 0.250 0.250 

An (ft2) 3.41E-04 3.41E-04 3.41 E-04 

A VG DH (in H20) 1.68 1.54 1.56 

P A TM (in Hg) 29.55 29.55 29.55 

Pm (in Hg) 29.67 29.66 29.67 

Ps (GAUGE) -0.54 -0.54 -0.54 

Ps (IN HG) 29.51 29.51 29.51 

Tm (F) 94.38 87.31 81.60 

Tm (R) 554.05 546.98 541.27 

Vm (ft3) 43.94 40.91 40.93 

Vm STD (ft3) 42.94 40.48 40.93 

VLQ (ml) 43.00 44.00 44.60 

VV STD (ft3) 2.03 2.07 2.10 

V STD (ft3) 44.97 42.56 43.03 

%M 4.51 4.87 4.88 4.76 

MD 0.955 0.951 0.951 

MWD 28.94 28.94 28.93 

M 28.44 28.40 28.40 

Ts (F) 205.63 206.29 207.67 206.53 

Ts (R) 665.30 665.96 667.34 666.20 

SUM SQRTDP 16.87 16.30 16.48 

N DP 24.00 24.00 24.00 

A VG SQRT DP 0.70 0.68 0.69 

CP 0.84 0.84 0.84 

Vs (ft/s) 44.94 43.46 43.99 44.13 

Ds (in) 59.25 59.25 59.25 

As(fl2) 19.15 19.15 19.15 

QS, FLOW, ACFM 51629 49929 50539 50699 

Q STD (ft3/min) 40413 39044 39439 39632 

Q STD DRY, FLOWSCFM 38592 37141 37513 37749 

WT(gm) 6.8800E-05 5.3200E-04 5.2800E-04 

%1 104.23 102.10 102.21 

%C02 1.0.0 1.00 1.00 1.00 

%02 19.41 19.39 19.37 19.39 

%C0 0.00 0.00 0.00 

%N2 79.59 79.61 79.63 

PMRc (Ibs/hr). '< 0.008 0.065 0.064 0.046 

Cs (GR/SCFD) • 0.00002 0.00020 0.00020 0.0001 

Page 15 of 202 
DATE 

SOURCE 

Run #1 

POINT # 

ISOKINETIC DATA AND CALCULATIONS 

10/16/O2 

Tunnel Kiln #1 

Tm 

K= 3.3869015 

dp dH SQRT DP % 02 

A 1 86 204 0.560 1.90 0.748 19.3 

A2 90.5 205 0.540 1.83 0.735 19.4 

A3 95.5 205 0.540 1.83 0.735 19.5 

;44 98.5 206 0.550 1.86 0.742 19.4 

A5 102.5 206 0.580 1.96 0.762 19.5 

A6 100 207 0.550 1.86 0.742 19.3 

A7 100.5 206 0.510 1.73 0.714 19.4 

;48 101.5 206 0.500 1.69 0.707 19.5 

A9 102 206 0.470 1.59 0.686 19.3 

A 10 100.5 206 0.450 1.52 0.671 19.4 

;4 11 101.5 205 0.450 1.52 0.671 19.5 

A 12 95 203 0.380 1.29 0.616 19.4 

B1 89.5 205 0.480 1.63 0.693 19.6 

B2 90 207 0.510 1.73 0.714 19.6 

B3 89.5 207 0.500 1.69 0.707 19.5 

B4 90 207 0.500 1.69 0.707 19.4 

B5 89.5 207 0.500 1.69 0.707 19.5 

B6 92 207 0.500 1.69 0.707 19.4 

B7 91 206 0.510 1.73 0.714 19.4 

B8 90.5 206 0.510 1.73 0.714 19.3 

B9 92.5 205 0.490 1.66 0.700 

BIO 94.5 205 0.490 1.66 0.700 

Bll 91 205 0.450 1.52 0.671 

B12 91 203 0.370 1.25 0.608 

94.38 

Vm(ft3) 

205.63 

Initial 119.06 

Final 163.00 

Total 43.94 

1.68 16.871 19.43 

corrected per 6C-1 19.41 

% N2 (BY DIFFERENCE• 

%Excess Air 

Calibration Actual 

Gas 

Zero 0.0 

Mid-Range 10.6 

• 19.0 

Calibration Data 

Instrument Reading 

Pre- -Post Pre0.2 0.2 0,95 

10.7 10.7 0.48 

19.2 n/a 0.95 

Based upon 2% of span value (21%) 

% Error* 

% C02 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1.00 

79.59 

1215.00 

-Post 

0.95 

0.48 

n/a 

Page 16 of 202 
DATE 

SOURCE 

Run #2 

POINT # 

ISOKINETIC DATA AND CALCULATIONS 

10/16/02 

Tunnel Kiln #1 

7"m 

3,341 

dH SQRT DP % 02 % C02 

A 1 83.0 202 0.470 1.57 0.686 19.4 

A2 86.5 205 0.490 1.64 0.700 19.3 

A3 88.0 206 0.490 1.64 0.700 19.3 

A4 87.5 206 0.490 1.64 0.700 19.5 

A5 88.0 206 0.510 1.70 0.714 19.5 

A6 89.0 207 0.440 1.47 0.663 19.5 

A7 89.5 208 0.470 1.57 0.686 19.4 

A8 87.0 208 0.430 1.44 0.656 19.4 

A9 87.5 209 0.420 1.40 0.648 19.3 

A 10 88.5 208 0.400 1.34 0.632 19.5 

All 89.0 208 0.420 1.40 0.648 19.5 

A 12 88.5 207 0.430 1.44 0.656 

B1 86.5 206 0.470 1.57 0.686 19.2 

B2 87.5 207 0.430 1.44 0.656 19.4 

B3 87.0 206 0.500 1.67 0.707 19.4 

B4 87.5 206 0.500 1.67 0.707 19.5 

B5 87.5 206 0.490 1.64 0.700 19.6 

B6 87.0 205 0.510 1.70 0.714 19.3 

B7 87.0 206 0.500 1.67 0.707 19.4 

B8 87.0 207 0.480 1.60 0.693 

B9 87.5 207 0.460 1.54 0.678 

BIO 86.5 207 0.450 1.50 0.671 

B11 86,0 205 0.440 1.47 0.663 

B12 86.5 203 0.390 1.30 0.624 

87.31 

Vm(ft3) 

206.29 

Initial 163.62 

Final 204.53 

Total 40.91 

1.54 16.295 19.41 

corrected per 6C- 1 19.39 

% N2 (BY DIFFERENCE• 

%Excess Air 

Calibration Actual 

Gas 

Zero 0.0 

Mid-Range 10.6 

Hi-Rang• 19.0 

Based upon 2% of span value (21%) 

Calibration Data 

Instrument Reading 

Pre- -Post Pre0.2 0.2 0.95 

10.7 10.7 0.48 

n/a n/a n/a 

% Error* 

1 

1.00 

79.61 

1195.77 

-Post 

0.95 

0.48 

n/a 

Page 17 of 202 
DATE 

SOURCE 

Run #3 

POINT # 

ISOKINETIC DATA AND CALCULATIONS 

10/16/02 

Tunnel Kiln #1 

Tm 

K= 3,3104673 

dp dH SQRT DP % 02 

A 1 80.0 207 0.500 1.66 0.707 19.4 

A2 80.5 208 0.510 1.69 0.714 19.4 

A3 81.0 209 0,510 1.69 0.714 19.3 

A4 82.0 209 0.520 1.72 0,721 19,3 

A5 82.5 209 0.530 1.75 0.728 19.5 

A6 83.5 208 0,470 1.56 0.686 19,5 

A7 83.5 208 0.480 1.59 0.693 19.4 

A8 83.5 210 0.470 1,56 0.686 19.6 

A9 83.0 208 0.450 1.49 0,671 19.4 

A 10 83.0 208 0.440 1.46 0,663 19,4 

A 11 83.0 206 0.430 1.42 0.656 19.4 

A12 83.0 206 0,360 1,19 0.600 

B1 79.5 206 0.520 1.72 0.721 19.3 

B2 80.0 206 0,560 1.85 0.748 19.3 

B3 81.5 207 0.530 1.75 0.728 19.4 

B4 82.0 207 0.510 1.69 0.714 19.5 

B5 82.0 208 0.490 1.62 0.700 19.6 

B6 82.0 208 0,430 1.42 0.656 19.6 

B7 80.5 209 0.460 1.52 0,678 

B8 80.5 209 0.440 1.46 0.663 

B9 81.0 208 0,450 1.49 0.671 

BIO 80.5 208 0.450 1.49 0.671 

Bll 80.0 206 0.440 1.46 0.663 

B12 80.5 206 0.390 1,29 0.624 

81.60 

Vm(ft3) 

207.67 

Initial 204.66 

Final 245.59 

Total 40.93 

1.56 16.477 19.43 

corrected per 6C-1 19.37 

% N2 (BY DIFFERENCE• 

%Excess Air 

Calibration Actual 

Gas 

Zero 0.0 

Mid-Range 10. 6 

H R a n_.n_.n_.n_.n_.n_• 19,0 

Calibration Data 

Instrument Reading 

Pre- -Post Pre0.2 0.1 0.95 

10.7 10.7 0.48 

n/a n/a n/a 

Based upon 2% of span value (21%) 

% Error* 

% C02 

1 

1.00 

79.63 

1173.04 

-Post 

0.48 

0.48 

n/a 

Page 18 of 202 
MOISTURE DATA 

Run #1 

1st Imp. 2nd Imp. 3rd Imp. 4th Imp. 

BEGINNING 100.00 100.00 200.00 300.00 

ENDING 114.00 108.00 204.00 317.00 

NET 14.00 8.00 4.00 17.00 

TOTALS 

43.0 

Run #2 

1st Imp. 2nd Imp. 3rd Imp. 4th Imp. 

BEGINNING 100.00 100.00 200.00 300.00 

ENDING 118.00 104.00 204.00 318.00 

NET 18.00 4.00 4.00 18.00 

TOTALS 

44 

Run #3 

1st Imp. 2nd Imp. 3rd Imp. 4th Imp. 

BEGINNING 100.00 100.00 200.00 300.00 

ENDING 117.00 104.00 205.00 318.60 

NET 17.00 4.00 5.00 18.60 

TOTALS 

44.6 

Page 19 of 202 
ISOKINETIC SAMPLING RATE CALCULATION 

dH KdP 

K (846.72*Dn^4*dH @*Cp^2"(1 -Bw)^2*Md*Tm,Ps)/(Ms,Ts,Pm) 

Run #1 Run #2 Run #3 

Dn 0.250 0.250 0.250 

dH@ 1.87 1.87 1.87 

Y, gamma factor 1.03 1.03 1.03 

Cp 0.84 0.84 0.84 

Bw(FRA CTION, NOT%) 0.05 0.05 0.05 

Md 29.00 29.00 29.00 

Pbar 29.55 29.55 29.55 

PS (GAUGE) -0.54 -0.54 -0.54 

Ps 29.51 29.51 29.51 

Tm, F 90.00 95.00 90.00 

Tm, R 549.67 554.67 549.67 

Ms 28.45 28.45 28.45 

Ts, F 190.00 205.00. 205.00 

Ts, R 649.67 664.67 664.67 

Pm 29.66 29.66 29.66 

K 3.3869 3.3406 3.3105 

TERMINOLOGY 

Ms=APPARENT STACK GAS MOLECULAR WEIGHT 

=Md(1-Bw)+18Bw 

Md=DRY GAS MOLECULAR WEIGHT (29) OR 

=(0.44*%CO2)+(0.32*%O2)+(0.28*(%N2+%CO)) 

Ps GAUGE=STACK STATIC PRESSURE (IN. H20) 

Ps=ABSOLUTE STACK PRESSURE (IN. Hg) 

Pm=METER ABSOLUTE PRESSURE (IN. Hg) 

Pbar + (avg dH/13.6) 

Page 20 of 202 
PARTICULATE EMISSION RATE CALCULATION 

L OCA TION: Boral Bricks 

SOURCE: Tunnel Kiln #1 

DATA Run #4 Run #5 Run #6 AVERAGE 

DATE 10/17/02 10/17/02 10/17/02 

RUN TIME (min) 60.00 60.00 60.00 

Dn (in) 0,250 0.250 0.250 

An (ft2) 3.41E-04 3.41 E-04 3.41E-04 

A VG DH (in H20) 1.44 1.47 1.36 

P A TM (in Hg) 29.64 29.64 29.64 

Pm (in Hg) 29.75 29.75 29.74 

Ps (GAUGE) -0.54 -0.54 -0.54 

Ps (IN HG) 29.60 29.60 29.60 

Tm (F) 78.33 74.27 86.33 

Tm (R) 538.00 533.94 546.00 

Vm (ft3) 39.14 39.91 38.82 

Vm STD (ft3) 39.49 40.57 38.58 

VLQ (ml) 33.60 31.70 32.50 

VV STD (ft3) 1.58 1.49 1.53 

VSTD(ft3) 41.07 42.07 40.12 

%M 3.86 3.55 3.82 3.74 

MD 0.961 0.964 0.962 

MWD 28.93 28.93 28.94 

M 28.51 28.54 28.52 

Ts (F) 203.25 202.83 202.75 202.94 

Ts (R) 662.92 662.50 662.42 662.61 SUM SQRT DP 15.95 16.12 15.52 

N DP 24.00 24.00 24.00 

A VG SQRTDP 0.66 0.67 0.65 

CP 0.84 0.84 0.84 

Vs (fYs) 42.29 42,70 41.14 42.04 

Ds (in) 59.25 59.25 59.25 

As(ft2) 19.15 19.15 19.15 

QS, FLOW, ACFM 48579 49056 47265 48300 Q STD (ft3/min) 38279 38678 37271 38076 Q STD DRY, FLOW SCFM 36802 37304 35847 36651 

WT (gin) 0.0018 0.0035 0.0038 

%1 100.50 101.88 100.82 

%C02 1.00 1.00 1.00 1.00 

%02 19.30 19.31 19.44 19.35 

%C0 0.00 0.00 0.00 

%N2 79.70 79.69 79.56 

PMRc (Ibs/hr) 0.222 0.426 0.467 0.372 Cs (GR/SCFD) 0.0007 0.0013 0.0015 0.0012 

Page 21 of 202 
HCI EMISSION RATE CALCULATION 

L OCA TION: Boral Bricks 

SOURCE: Tunnel Kiln #1 

DATA Run #4 Run #5 Run #6 AVERAGE 

DATE 10/17/02 10/17/02 10/17/02 

RUN TIME (rain) 60.00 60.00 60.00 

Dn (in) 0.250 0.250 0.250 

An (ft2) 3.41E-04 3.41E-04 3.41E-04 

AVG DH (in H20) 1.44 1.47 1.36 

P ATM (in Hg) 29.64 29.64 29.64 

Pm (in Hg) 29.75 29.75 29.74 

Ps (GAUGE) -0.54 -0.54 -0.54 

Ps (IN HG) 29.60 29.60 29.60 

Tm (F) 78.33 74.27 86.33 

Tm (R) 538.00 533.94 546.00 

Vm (ft3) 39.14 39.91 38.82 

Vm STD (ft3) 39.49 40.57 38.58 

VLQ (ml) 33.60 31.70 32.50 

VV STD (ft3) 1.58 1.49 1.53 

V STD (ft3) 41.07 42.07 40.12 

%M 3.86 3.55 3.82 3.74 

MD 0.961 0.964 0.962 

MWD 28.93 28.93 28.94 

M 28.51 28.54 28.52 

Ts (F) 203.25 202.83 202.75 202.94 

Ts (R) 662.92 662.50 662.42 662.61 

SUM SQRT DP 15.95 16.12 15.52 

N DP 24.00 24.00 24.00 

A VG SQRT DP 0.66 0.67 0.65 

CP 0.84 0.84 0.84 

Vs (ft/s) 42.29 42.70 41.14 42.04 

Ds (in) 59.25 59.25 59.25 

As (ft2) 19.15 19.15 19.15 

QS, FLOW, ACFM 48579 49056 47265 48300 

Q STD (ft3/min) 38279 38678 37271 38076 

Q STD DRY, FLOW SCFM 36802 37304 35847 36651 

WT (gm) 3.3200E-04 2.5000E-04 3.5500E-04 

%1 100.50 101.88 100.82 

%C02 1.00 1.00 1.00 1.00 

%02 19.30 19.31 19.44 19.35 

%C0 0.00 0.00 0.00 

%N2 79.70 79.69 79.56 

PMRc (Ibs/hr) 0.041 0.030 0.044 0.038 

Cs(GR/SCFD) 0.00013 0.00010 0.00014 0.00012 

Page 22 of 202 
HF EMISSION RATE CALCULATION 

LOCATION: Boral Bricks 

SOURCE: Tunnel Kiln #1 

DATA Run #4 Run #5 Run #6 AVERAGE 

DATE 10/17/02 10/17/02 10/17/02 

RUN TIME (rain) 60.00 60.00 60.00 

Dn (in) 0.250 0.250 0.250 

An (fi2) 3.41E-04 3.41E-04 3.41E-04 

A VG DH (in H20) 1.44 1.47 1.36 

P ATM (in Hg) 29.64 29.64 29.64 

Pm (in Hg) 29.75 29.75 29.74 

Ps (GAUGE) -0.54 -0.54 -0.54 

Ps (IN HG) 29.60 29.60 29.60 

Tm (F) 78.33 74.27 86.33 

Tm (R) 538.00 533.94 546.00 

Vm (ft3) 39.14 39.91 38.82 

Vm STD (ft3) 39.49 40.57 38.58 

VLQ (ml) 33.60 31.70 32.50 

VV STD (ft3) 1.58 1.49 1.53 

V STD (ft3) 41.07 42.07 40,12 

%M 3.86 3.55 3.82 3,74 

MD 0,961 0,964 0.962 

MWD 28.93 28.93 28.94 

M 28.51 28.54 28.52 

Ts (F) 203.25 202.83 202.75 202.94 

Ts (R) 662.92 662.50 662.42 662.61 

SUM SQRT DP 15.95 16.12 15.52 

N DP 24.00 24.00 24.00 

A VG SQRT DP 0.66 0.67 0.65 

CP 0.84 0.84 0.84 

Vs (ft/s) 42.29 42.70 41.14 42.04 

Ds (in) 59.25 59.25 59.25 

As (ft2) 19.15 19.15 19.15 

QS, FLOW, ACFM 48579 49056 47265 48300 

Q STD (ft3/min) 38279 38678 37271 38076 

Q STD DRY, FLOW SCFM 36802 37304 35847 36651 

WT(gm) 5.3800E-05 5.2900E-05 5.4000E-05 

%1 100.50 101.88 100.82 

%C02 1,00 1.00 1.00 1.00 

%02 19.30 19.31 19.44 19.35 

%C0 0.00 0.00 0.00 

%N2 79.70 79.69 79.56 

PMRc (Ibs/hr) 4, 0.007 '< 0.006 < 0.007 • 0.007 

Cs (GR/SCFD) <• 0.00002 • 0.00002 •" 0.00002 •" 0.00002 

Page 23 of 202 
DATE 

SOURCE 

Run #4 

POINT # 

ISOKINETIC DATA AND CALCULATIONS 

I 0/17/02 

Tunnel Kiln #1 

Tm 

K= 3.2502907 

dp dH SQRT DP % 02 

A 1 80 199 0.410 1.33 0.640 19.7 

A2 80 201 0.430 1.40 0.656 19.6 

A3 80.5 205 0.450 1.46 0.671 19.6 

A4 81 202 0.470 1.53 0.686 19.6 

A5 81 203 0.470 1.53 0,686 19.6 

A8 81.5 203 0.480 1.56 0.693 19.5 

A7 82 203 0.460 1.50 0.678 19.5 

A8 82 204 0.460 1.50 0.678 19.6 

A9 82 204 0.430 1.40 0.656 19.5 

A 10 82 204 0.410 1.33 0.640 19.5 

A 11 82 202 0.400 1.30 0.632 19.7 

A 12 82.5 203 0.380 1.24 0.616 

B1 77 204 0.460 1.50 0.678 19.7 

B2 76.5 205 0.460 1.50 0.678 19.6 

B3 76 205 0.470 1.53 0.686 19.6 

B4 75.5 205 0.470 1.53 0.686 19.4 

B5 75.5 205 0.490 1.59 0,700 19.3 

B6 75 205 0.500 1.63 0.707 19.3 

B7 75 204 0.450 1.46 0.671 19.1 

B8 75.5 204 0.430 1.40 0.656 19.2 

B9 75.5 203 0.440 1.43 0.663 19.2 

BIO 74 203 0.420 1.37 0.648 19.2 

B11 74 202 0.410 1.33 0.640 19.5 

B12 74 200 0.360 1.17 0.600 

78.33 

Vm(ft3) 

203.25 

Initial 245.92 

Final 285.06 

Total 39.14 

1.44 15.945 19.48 

corrected per 6C- 1 19.30 

% N2 (BY DIFFERENCE• 

%Excess Air 

Calibration Actual 

Gas 

Zero 0,0 

Mid-Range 10.6 

Hi-Ran__g• 19.0 

Calibration Data 

Instrument Reading 

Pre- -Post Pre0.0 0 0.00 

10.7 10.7 0.48 

19.2 n/a 0.95 

Based upon 2% of span value (21%) 

% Error* 

% C02 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1.00 

79.70 

1104.60 

-Post 

0.00 

0.48 

n/a 

Page 24 of 202 
DATE 

SOURCE 

Run #5 

POINT # 

ISOKINETIC DATA AND CALCULATIONS 

10/17/O2 

Tunnel Kiln #1 

Tm 

K• 3.250 

dH SQRT DP % 02 % C02 

A 1 69.5 204 0,460 1.50 0.678 19.3 

A2 69.5 204 0,470 1.53 0.686 19.6 

A3 71.5 204 0.480 1.56 0.693 19.6 

A4 74.0 204 0.510 1.66 0.714 19.6 

A5 75.0 204 0.510 1.66 0.714 19.5 

A6 74.5 204 0.510 1.66 0.714 19.5 

A7 74.0 205 0.480 1.56 0.693 19.4 

A8 73.5 205 0.460 1.50 0.678 19.5 

A9 74.0 205 0.420 1.37 O. 648 19.5 

A 10 73.5 204 0.400 1.30 0.632 19.6 

All 73.5 203 0.380 1.24 0.616 19.7 

A 12 74.5 203 0.360 1.17 0.600 

B1 73.5 202 0.450 1.46 0.671 19.5 

B2 75.0 203 0.470 1,53 0.686 19.4 

B3 75.0 203 0.490 1.59 0.700 19.3 

B4 75.0 203 0.500 1.63 0.707 19.4 

B5 74.5 203 0.500 1.63 0.707 19.3 

B6 75.5 202 0.480 1.56 0.693 19.4 

B7 76.5 202 0.430 1.40 0.656 19.5 

B8 76.5 201 0.440 1.43 0.663 19.5 

B9 76.5 200 0.450 1.46 0.671 19.3 

BIO 77.5 200 0.440 1.43 0.663 19.2 

Bll 75.0 200 0.400 1.3O 0.632 19.3 

B12 75.0 200 0.360 1.17 0.600 

74.27 

Vm(ft3) 

202.83 

Initial 285.18 

Final 325.09 

Total 39,91 

1.47 16.116 19.45 

corrected per 6C- 1 19. 31 

% N2 (BY DIFFERENCE• 

%Excess Air 

Calibration Actual 

Gas 

Zero 0,0 

Mid-Range 1 0.6 

• 19.0 

Calibration Data 

Instrument Reading 

Pre- -Post Pre0.0 0.1 0.00 

10.7 10.7 0.48 

n/a n/a n/a 

Based upon 2% of span value (21%) 

% Error* 

1 

1 

1 

1 

1 

1 

1 

1.00 

•.• 

1116.43 

-Post 

0.48 

0.48 

n/a 

Page 25 of 202 
DATE 

SOURCE 

Run #6 

POINT # 

ISOKINETIC DATA AND CALCULATIONS 

10/17/02 

Tunnel Kiln #1 

Tm 

K= 3,2502907 

dp dH SQRT DP % 02 

A 1 84.0 201 0.430 1.40 0.656 19.5 

A2 84.5 202 0.430 1.40 0.656 19.6 

A3 86.0 202 0.460 1.50 0.678 19.6 

A4 86.5 203 0.470 1.53 0.686 19.6 

A5 87.0 203 0.470 1.53 0.686 19.5 

A6 87.0 203 0.470 1.53 0.686 19.6 

A 7 86.0 203 0.440 1.43 0.663 19.6 

A8 86.0 203 0.410 1.33 0.640 19.4 

A9 85.0 203 0.390 1.27 0.624 19.4 

A 10 85.5 204 0,390 1.27 0.624 19.5 

A 11 85.0 204 0.380 1.24 0.616 19.7 

A 12 85.0 204 0.340 1.11 0.583 

B1 82.5 201 0.490 1.59 0.700 19.4 

B2 84.5 203 0.450 1.46 0.671 19.5 

B3 85.5 204 0.440 1.43 0.663 19.5 

B4 85.5 205 0.450 1.46 0.671 19.6 

B5 85.5 205 0.450 1.46 0.671 19.4 

B6 86.5 205 0.410 1.33 0.640 19.5 

B7 87.0 204 0,420 1.37 0.648 19.7 

B8 88.5 204 0.410 1.33 0.640 19.6 

B9 89.0 203 0.420 1,37 0.648 19.6 

BIO 89.5 202 0.400 1.30 0.632 

Bll 89,5 197 0.360 1.17 0.600 

B12 91.0 198 0.290 0.94 0.539 

86.33 

Vm(ft3) 

202.75 

Initial 325.72 

Final 364.54 

Total 38.82 

1.36 15.522 19.54 

corrected per 6C-1 19.44 

% N2 (BY DIFFERENCE• 

%Excess Air 

Calibration Actual 

Gas 

Zero 0.0 

Mid-Range 10.6 

Hi-Rang• 19.0 

Calibration Data 

% C02 

1.• 

79.• 

1243.• 

Instrument Reading % Error* 

Pre- -Post Pre- -Post 

0.1 0.1 0.48 0.48 

10.7 10.7 0.48 0.48 

n/a n/a n/a n/a 

1 

1 

1 

1 

1 

Based upon 2% of span value (21%) 

Page 26 of 202 
MOISTURE DATA 

Run #4 

BEGINNING 

ENDING 

NET 

lstlmp. 2ndlmp. 3rdlmp. 4• Imp. 

100.00 100.00 200,00 300°00 

112.00 108.00 205.00 308.60 

12.00 8.00 5.00 8.60 

TOTALS 

33.6 

Run #5 

BEGINNING 

ENDING 

NET 

lstlmp. 2ndlmp. 3rdlmp. 4• Imp. 

100.00 100.00 200.00 300.00 

117.00 105,00 204.00 305.70 

17.00 5.00 4.00 5.70 

TOTALS 

31.7 

Run #6 

BEGINNING 

ENDING 

NET 

lstlmp. 2ndlmp. 3rdlmp. 4• Imp. 

100.00 100.00 200.00 300.00 

116.00 104.00 204.00 308.50 

16.00 4.00 4.00 8.50 

TOTALS 

32.5 

Page 27 of 202 
ISOKINETIC SAMPLING RATE CALCULATION 

dH KdP 

K (846.72*Dn^4*dH @*Cp^2"(1 -Bw)^2*Md*Tm*Ps)/(Ms*Ts*Pm) 

Run #4 Run #5 Run #6 

Dn 0,250 0.250 0.250 

dH@ 1.87 1.87 1.87 

Y, gamma factor 1.03 1.03 1,03 

cp 0.84 0.84 0.84 

Bw(FRACTION•NOT%) 0.05 0.05 0.05 

Md 29.00 29.00 29.00 

Pbar 29.64 29.64 29.64 

PS (GAUGE) -0.54 -0.54 -0.54 

Ps 29.60 29.60 29.60 

Tin, F 80.00 80.00 80.00 

Tm, R 539.67 539.67 539.67 

Ms 28.45 28..45 28.45 

Ts, F 205.00 205.00 205.00 

Ts, R 664,67 664.67 664.67 

Pm 29.75 29.75 29.75 

K 3.2503 3.2503 3.2503 

TERMINOL OG ¥ 

Ms=APPARENT STACK GAS MOLECULAR WEIGHT 

=Md(1 -Bw)+18Bw 

Md=DRY GAS MOLECULAR WEIGHT (29) OR 

=(0.44*%CO2)+(0.32*%O2)+(0.28*(%N2+%CO)) 

Ps GAUGE=STACK STATIC PRESSURE (IN. H20) 

Ps=ABSOLUTE STACK PRESSURE (IN. Hg) 

Pro=METER ABSOLUTE PRESSURE (IN. Hg) 

Pbar + (avg dH/13.6) 

Page 28 of 202 
SAMPLE CALCULATIONS 

Boral Bricks 

Augusta, GA 

Run #1 

1) ABSOLUTE PRESSURE IN DRY GAS METER 

Pm= P ATM + AVG DH/13.6 

P ATM Avg. DH Pm 

T STD 

P STD 

29.55 1.68 

2) ABSOLUTE STACK PRESSURE 

Ps P ATM + Ps(GAUGE)/13.6 

29.67 

P ATM Ps(GAUGE) Ps 

29.55 -0.54 29.51 

3) SAMPLE VOLUME AT STANDARD CONDITIONS 

VM STD (VM)*(Y)*(T STD/TM)*(PM/P STD) 

Vm Tm Y Vm STD 

43.94 554.05 1.034 42,94 ft3 

4) VOLUME OF WATER COLLECTED, CORRECTED TO STANDARD CONDITIONS 

VV STD VV STDw + VVSTDsg 

VV S'EDw (.002673)*(VLQw)*(T STD/P STD) 

VV STDsg (.002668)*VLQsg)*(T STD/P STD) 

WHERE 0.002673 0.04707 FT3/ML*IN. HG/17.64 DEG. R. 

WHERE 0.002668 0.04715 FT3/G*IN.HG/17.64 DEG. R. 

VLQ (w) VLQ (sg) VV STD 

26.00 17,00 2.03 ft3 

5) TOTAL SAMPLE VOLUME AT STANDARD CONDITIONS 

V STD Vm STD + VV STD 44.97 ft3 

6) PERCENT MOISTURE IN STACK GAS 

%M (100)*(VV STD)/V STD 4,51% 

7) MOLE FRACTION OF DRY GAS 

MD (100-%M)/100 0.955 

528 DEG R. 

29.92 IN. HG 

Page 29 of 202 
SAMPLE CALCULATIONS 

7A) MOLECULAR WEIGHT OF THE DRY GAS 

MWD (%CO2*0.44)+(O2*0.32)+((%CO+%N2)*0.28) 

%CO2 %02 %CO %N2 MWD 

1.00 19.41 0.00 79.59 28.94 

8) MOLECULAR WEIGHT OF THE WET GAS 

M (MWD)*(MD) + 18(1-MD) 28.44 

WHERE 18 MOLECULAR WEIGHT OF WATER, G/G-MOLE 

9) STACK VELOCITY 

VS (85.49)*(CP)*((TS/(PS)(M))^1/2*((SUM SQRT DP)/N DP)) 

where 85.49 ff/sec* [Ib/Ib-mole*in.Hg)/(deg. R'in H20)]^0.5 

CP Ts (R) SUM SQRT N DP VS 

0.84 665.30 16.87 24 44.94 

10) STACK VOLUMETRIC FLOW RATE 

QS (60)*(VS)*(AS) 

AS (inlet) QS 

19.15 51629 

11) STACK VOLUMETRIC FLOW RATE, STANDARD CONDITIONS INCLUDING MOISTURE 

Q STD Q STD DRY/MD 40413 

12) STACK VOLUME FLOW RATE STANDARD CONDITIONS DRY 

Q STD DRY= 17.647*60*Md*Vs*A*(Ps/Ts(R)) 38592 

13) POLLUTANT MASS RATE, CONCENTRATION BASIS 

PMRC (. 1323)*(WT)*(Q STD)/V STD 

WHERE 0.1323 COMBINED CONVERSION FACTOR (60 MIN/HR*0.00220 LBS/GRAM) 

WT(GRAMS) PMRC 

0.0007 0.083 

14) PERCENT ISOKINETIC 

%1 (0.09450*Ts*Vm std)/(Ps*Vs*An*Time*Md) 

Run Time Area of Nozzle 

60 3.41E-04 

%1 

104,23 

15) CONCENTRATION, GPJSCFD 

Cs= 15.43 gr/gm WT/Vm STD 

Cs 0.0003 

Page 30 of 202