Entec Services, Inc. 16 D Commerce

Avenue Hueytown, Alabama

35023 Telephone: (205) 491-6676 Fax: (205) 491-6614 Results of the February

7-8, 2006 Engineering / Compliance

Testing

for Particulate, HCL/HF

and Sulfuric

Acid Mist Emissions

on the Brick Kiln Stack Located at the Muskogee

Facility In Muskogee,

Oklahoma Submitted to: Boral Bricks P.O. Box 1178 Columbus, Georgia

31902

Attention: Mr. Frank Porter Entec Project

No. 36114 Completed By:

Project Manager Report

Submitted:

February

22, 2006

Tom Lotz, St. QA/QC 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.Executive Summary Entec Services,

Inc. was retained

by Boral Bricks to perform

Particulate,

HCL/HF

and Sulfuric Acid Mist emissions

testing

on the Brick Kiln Stack at the Muskogee

facility located in Muskogee,

Oklahoma.

Mr. Lalan Kirby and Mr. Erik Groth of Entec Services, Inc. conducted

the testing on February

7-8, 2006. No difficulties

were encountered

in the field collection

of the samples

or in the laboratory analysis

of the samples

by Entec

Services,

Inc. or by Stillbrook Environmental Testing

Lab, Inc.
The emissions

test summary

on the following

page gives a detailed

summary

of each test run.

10 D "-" (•

000

0 0i Deta led

Test

ResultsEntec Services, Inc. SOURCE OVERVIEW

SOURCE OWNER: PLANT LOCATION: SOURCE(S) NAME(S): SOURCE(S) CONDITION: SOURCE(S) SHAPE: PROBE WASH CHEMICAL: TEST PERFORMED: REFERENCE METHOD

TESTS:

PROJECT MANAGER ENVIRONMENTAL ANALYST

PROJECT

LEADER ENVIRONMENTAL ANALYST

ASSISTANT OWNER'S REPRESENTATIVE: DATES TESTS CONDUCTED: ENTEC PROJECT

NUMBER: Boral Brick Muskogee, Oklahoma Brick Kiln Engineering, Compliance

Grade Testing Circular Acetone Particulate and HCL Testing Sample Location Volumetric Flow Molecular Weight Moisture Content Particulate Hydrogen Chloride

EPA Method EPA Method EPA Method EPA Method EPA Method EPA Method Mr. Tommy Lotz, Jr. Mr. Lalan Kirby Mr. Edk Groth MroFrank Porter 02/07/06 36114 1234526AENTEC Services,

Inc.

INPUT TEST DATA Client: Boral Brick Job No.:

36114 Source: Brick Kiln Data Input By:

Lalan Kirby 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 @ Nozzle Diameter Meter Volume Meter Temperature Avg. Orifice Delta H Impingers Weight Gain (Moisture) Silica Gel lmpinger Weight Gain (Moisture) Oxygen Concentration,

dry basis Carbon Dioxide Concentration,

dry basis Avg. Sq. Rt. of Delta P Stack Temperature Total Hydrogen

Chloride collected,

mg Total Hydrogen

Fluoride collected,

mg Total particulate

collected Symbol

0AsPbarCp
Y•H@OnVrn

AHWimp

COz (sqrt

HCLHF

Units

Military Time 02/07/06 1129-1236

Test Data
02/07/06 1316-1419 02/07/06 1456-1600 minutes 60

60

60 F• 19.635

19.635

19.635 in. Hg in. H20

in. H20 inches

29.90 -0.42 0.84 0.971 1.786 0.245 43.158 73.4 1.65 52.6 11.5 dcfF in. Hz0 grams grams %

18.0 % 3.0 0.912 461.5 5.82 125.00 113.2 (in. H20) llz Fmg 29.90 -0.45 0.84 0.971 1.786 0.245 45.153 84.8 1.67 58.68.718.03.0 0.917 461.6 6.08 131.00 101.3 mgmg

29.90 -0.46 0.84 0.971 1.786 0.245 45.723 84.11.71 58.5 10.218.03.0 0.931 470.0 6.34 137.00 97.4

AVERAGE

60

29.90 -0.44 0.84 0.971 1.786 0.245 44.678 80.8 1.68 56.6 10.1

0.920 464.4 6.08ENTEC Services,

inc. 16-D Commerce Ave, Hue•town. Alabama 35023 CALCULA1ED TEST DATA Client: Boral Brick Job No.:

36114 Source: Brick Kiln Data Input By: Lalan Kirby Description Formulas

Symbol

Units

Calculated Data Run Number 2

3 AVERAGE

Time BeUlah-Ended Military Time 1129-1236

1316-1419

1456-1600 iiiiiiiiiiiiiiii!iiiiiiiiiiiiiiiiiii!iiiil 1. Stack Pressure P• Pg 13,6 Ps in. Hg 29.87

29.87

29.87

29.87 2, Meter Pressure P•r &H 13.6 Pm in. Hg 30.02

30,02

30.03

30.02 3. Standard Meter Volume 17.64"Y* (vc,/'rm)* (P• ,•H 13.6) Vm(•)

dscf 41.608

42.621

43.219

42.483 4a. Standard Volume of Water Vapor Condensed =0.04706"W•.•,

v•=•

scf 2,475

2.758

2,753

2.662 4b. Standard Volume of Water Collected in Silica Gel =0.0471•'W•

v.,•,,•

scf 0.542

0.410

0.481

0.478 5. Moisture Fraction =(V•l=• Vws•l(Std))/(Vwc•std)

Vw•std Vm{stdl B• fraction

0.0676

0.0692

0.0696

0.0688 9, Molecular Weight Of Stack Gas, dW basis

0.32"(0•)+ 0.44"(c02)+0.28"(100-(02)-(c0=))

Md g/g-mole

29.200

29.200

29.200

29.200 10. Molecular Weight Of Stack Gas, wet basis M•*(1-Bws)+18.0*(l•)

I• g/g--mole

28,443

28.425

28,420

28.429 11. Average Stack Gas Velocity 85.49"C.*(sqrt ,•P).vg*SQRT((T.)

(P.*Mw)] v. rids 68.19

68.62

69.99

68.932 12, Stack Gas Flow @ Stack Conditions 60*vs*A• Q• acfra 80,332

80,838

82,455

81,208 13. Stack Gas Flow @ Standard Conditions Q.*(T,=EI",)*(P•/P,•,]

Q. scfra 45,930

46,211

46,712

46,284 !14. Stack Gas Flow @ Dry Standard Conditions Q.*(1-B.=)*(T=ET.)*(PJP=a]

Q• dscfm 42,824

43,014

43,460

43,100 14b, Hydrogen Chloride concentration

@ Std.Cond.,Grains/Cu.Ft. =(0.01543*HCLr•)IQst=

HCLcs grldscf

0,002

0,002

0.002

0.002 14b. Hydrogen Fluoride concentration

@ Std,Cond.,Grains/Cu,Ft. =(O.01543*HFrr•j)lQ.¢d

HFcs gr/dscf

0.046

0.047

0.049

0.048 15. Particulate concentration @ Standard Conditions =0.01543*rnr•V•{=td)

cs gr/dscf 0.0420

0,0367

0.0348

0,0378 15b. Hydrogen Chloride emissions, Ibs per hour

=(60R'000)*HCLQ=•*Q=•

HCl -Ibs/hr Ibslhr

0.79

0.81

0.84

0.82 15b. Hydrogen Fluoride emissions, Ibs per hour

=(60/7000)*HFQ•t•*Qst=

HF -Ibs/h¢ Ib$1hr

17.02

17.49

18.22

17 57 21. Particulate emissions {60/7000)*¢s*Q=•

PMR Ibll•r 15,41

13.52

12,96

13.97 22. Volume collected through nozzle =TJP,*[0.002669*V•=+

Vr,*Y*Po•I"m]

V. acf 78.052

80.100

81.999

80.050 23. Particulate concentration,

@ actual conditions =0.01543"rn#V.

c. grlacf 0.0224

0.0195

0.0183

0,0201 24. Isokinetic Sampling Rate, Percent t00*Vnl (60*v=*A.'6)

0/o 97.12

99.05

99.41

98.52

Post Meter Orifice Cal. (EMC ALT-009 Yqa) yD. iiiiiiiiii;i!i;;!i;ili;il;i!iiiiiii;i;;l

1.0033

0.9737

0.9723

0.9831 % Difference, (Calibration must be within 5% of original Y-factor) ::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: ol 24%Entec Services, Inc. SOURCE OVERVIEW
SOURCE OWNER: PLANT LOCATION: SOURCE(S) NAME(S): SOURCE(S) CONDITION: SOURCE(S) SHAPE: PROBE WASH CHEMICAL: TEST PERFORMED: REFERENCE METHOD

TESTS:

PROJECT MANAGER ENVIRONMENTAL ANALYST

PROJECT

LEADER ENVIRONMENTAL ANALYST

ASSISTANT OWNER'S REPRESENTATIVE: DATES TESTS CONDUCTED: ENTEC PROJECT

NUMBER: Boral Brick Muskogee, Oklahoma Brick Kiln Engineering, Compliance

Grade Testing Circular IPA and Water Sulfuric Acid Mist Sample Location Volumetric Flow Molecular Weight Moisture Content Sulfudc Acid Mist

EPA Method EPA Method EPA Method EPA Method EPA Method Mr. Tommy Lotz, Jr. Mr. Lalan Kirby Mr. Edk Groth Mr.Frank Porter 02•8•6 36114 12348ENTEC Services,

Inc. 16-D Commerce Ave Hues/town A abama 35023 INPUT TEST DATA Client: Boral Brick Job No.:

38114 Source: Brick Kiln Data Input By:

i•l=n Kirby 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 @ Iozzle 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 Avg. Sq. Rt. of Delta P Stack Temperature Symbol

Units Test Data 1 2 02/08/06 02/08/06 Military Time 0832-0935 minutes 60 A= FtZ

19.635 PbarCpY

DnVrn

WimpWs,•O2C02 in. Hg

29.70 in. H20

-0.56

in. H20 inches dcfF in. Hz0 grams grams % (sqrt/tP)av.

0.84

1028-1130 60 19.635 29.70 -0.52 0.84 0.971 0.971 1.786 1.786 0.245 46.149 80.6 1.75 23.5

18.0 2.0 0.938 481.7 0.245 45.429 83.3 1.72 25.9 28.018.51.5 0.931 484.7

3 02/08/06 1221-1323 6O 19.635 29.70 -0.52 0.84

AVERAGE

60

29.70 -0.53 0.84 0.971 0.971 1.786 1.786 0.245 0.245 45.43O 45.669 81.5 81.8 1.70 24.0 28.5 1.72 24.5 28.6 17.5 18.0 2.0 1.8 0.929 477.5 0.932 481.3ENTEC Services,

Inc.

Client: Boral Brick Job No.:

36114 Source: Brick Kiln Data Input By: Lalan Kirby Description Formulas

Symbol Units

Calculated Data 2 3 Run Number Test Date Time Began-Ended Military Time 1. Stack Pressure Pbar Pal 13.6 P= irL Hg 29.66 12. Meter Pressure Pbzr AH 13.6 Pm in. Hg 29.83 3. Standard Meter Volume 17.64" Y* (V,•T,,)* (Pbar &H 13.6 Vm{=,•) dscf 43.616 4a. Standard Volume of Water Vapor Condensed =0.04706*W•rnp

V, $cf 4b. Standard Volume of Water Collected in Silica Gel

=0.0471s*W,•

vw,•,,• scf 5. Moisture Fraction =(v•,,(,td• Vwsq(Stdi)/(Vw¢(•d)

Vwsq{sto) Vmistd) •s fraction

0.0539 9. Molecular Weight Of Stack Gas, dry basis 0.32"(O2)+ o.,•4*(coz)+o.28*(lOO-(Oz)-(co•) Md g/gomole

29.040 10. Molecular Weight Of Stack Gas, wet basis

•*(I-Bw,)+IS.0*(B,,}

M, gig-mole

02108/06

02/08/06

02/08/06 0832-0935 1028-1130

1221-1323

AVERAGE

29.66 29.66

29.66 29.83 29.82

29.83 42.716 42.859

43.064 1.129 1.151 1.344 1.347 1.106 1.219 1.377 1.320 0.0561

0.0546

0.0548 28.980 29.020

29.013 28.445 28.364

28.419

28.409 11. Average Stack Gas Velocity

85.49*Cp*(sqrt

&P)av,•*SQRT((Ts)

(P•*M,,)) v, Pals 71.16

70.81

70.36

70.775 12. Stack Gas Flow @ Stack Conditions 60*vs*A• Q= acfm 83,832

83,422

82,887

83,380 13. Stack Gas Flow @ Standard Conditions Q•*(Tst•JTs)*(PJPsCd)

Qs scfm 46,574

46,206

46,260

46,347 %. Stack Gas Flow @ Dry Standard Conditions

Qa*(loBws)*(Tsta/Ts)*(Ps/P•td)

Q•=e dscfm 44,066

43,614

43,737

43,805 16. Sulfur Dioxide (SO2) Gas Concentration From Titrations C,o• Ibs/dscf 2.04E-05

2.70E-05

2.82E-05

2.52E-05 16. Sulfuric Acid Mist (H2SO4) Gas Concentration From l"itrations C.•so Ibs/dscf 5.64E-06

6.11E-06

7.83E-06

6.53E-06 21. Sulfur Dioxide (SO2) Gas Concentration From TitraUons SO•-Ib/hr Ib/hr 53.97

70.73

73.89

66.20 21. Sulfuric Acid Mist (H2SO4) Gas Concentration From Titrations HzSO4-1b/hr

Ib/hr 14.91

15.98

20.55

17.15 22. Volume collected through nozzle

=T,/P,*[0.002669*V•c+

Vm*Y*P,n/Tm]

V. acf 82.974

81.702

81.220

81.966 24. Isokinetic Sampling Rate, Percent lO0*Vn/(60*v,*An*9)= % 98.94

97.90

97.95

98.26

Post Meter Orifice Cal. (EMC AL'r-009 Yqa) y ;iiiiiii•iiiiiiiiiiiiiiiiiiiiiiiii!

0 9774

0 9890

0 9789

0 9818 :•:•:i:i:i:!:i:!:i'"'.'.'.'.'. % Dfference (Ca brat must be th 5% of g Y+factor) ::::::::iil

•ii•iii;ii!•;;;;;•!•i!;i;i;i;;•:i•i;i;iii!i;iii::::iiiiii:::: ::iii 1•°/,Location of Test

PortsEntec Services,

inc 16 D Commerce

Ave. Hue}t,.town

AL 35023 STACK DRAWING

& TRAVERSE

POINT LOCATION Client: Boral Brick Job No. 36114 Source: Brick Kiln Input By: Lalan Kirby Type of Traverse: Velocity (V) or Particulate

(P):

P Stack Diamet•)r, inches:

• Stack Height, feet:

4• Stack Properties:

Inches

Duct Diameters Upstream Disturbance: Downstream Disturbance:

144.@

3.20 2.40

Port Type

Nipple Stack Area, Ft•: Number of Ports: Length of Port, inches: Total Number of Traverse Points: Number of Points per diameter:Port

Diameter

19.6352

2412 60.0

192.( NCHES

t44.0 •C.ES

Point No.

Inside Stack

Outside Nipple Inches Inches 1.3 6.3 2 4.0 9.0 3 7.1 12.1 4 10.6 15.6 5 15.0 20.0 6 21.4 26.4 7 38.6 43.6 8 45.0 50,0 9 49.4 54.4 10 52.9 57.9 11 56.0 61.0 12 58.7 63.7 Adjusted poinls diameter > 24" no point closer than 1.0 inch Adjusted points diameter _< 24" no point closer than 0.6 inch Stack Diameters between 12-24 inches minimum points are 8 4 points per port if the 812 diameters downstream

and upstream criteria is met,

12