Project No. 2761

CertainTeed Corporation

Wool Fiberglass Manufacturing Facility

Dry Electrostatic Precipitator and

Common Outlet Exhaust Stack

Emission Evaluation Test Report

December 2004
Prepared for:

Ms. Annjanette Ciliberto

CertainTeed Corporation

1220 Oak Hill Road

Crestwood Industrial Park

Mountaintop, Pennsylvania 18707-2199
Table of Contents

Page

1.0 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.0 Source Information and Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3.0 Test Results Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4.0 Sampling and Analytical Methodologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4.1 Cyclonic Flow Determination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4.2 Volumetric Flow Rate Determination . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.3 Moisture Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.4 Gaseous Emissions Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.4.1 Oxygen and Carbon Dioxide . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.4.2 Volatile Organic Compounds . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.4.3 Sulfur Dioxide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.4.4 Nitrogen Oxides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.5 Filterable and Condensible Particulate Matter . . . . . . . . . . . . . . . . 17

4.6 Toxic Metals - Arsenic, Chromium, and Lead . . . . . . . . . . . . . . . . . . 18

4.7 Particulate Matter/Phenol/Total Organic Carbon . . . . . . . . . . . . . 19

4.8 Formaldehyde . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.9 Ammonia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.10 Methanol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5.0 Quality Assurance/Quality Control Procedures . . . . . . . . . . . . . . . . . . . . . 24

5.1 S-Type Pitot Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5.2 Dry Gas Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5.3 Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5.4 Thermocouples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5.5 Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

5.6 Chain-of-Custody Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

5.7 Calibration Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Appendix A - Field Data 

Appendix B - Laboratory Data

Appendix C - Calculations

Appendix D - Calibration Data
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AirNova, Inc. 1

1.0 Introduction

AirNova, Inc. conducted an emission evaluation test program at the CertainTeed Corporation

facility located in Mountaintop, Pennsylvania on December 2 and 3, 2004. Emission sampling was

conducted to evaluate the Dry Electrostatic Precipitator (Dry EP) control device and the Common Outlet

Exhaust Stack in operation at this facility. 

The specific parameters which were determined as part of this emission test program included

the following:

C Volatile Organic Compounds

C Sulfur Dioxide

C Nitrogen Oxides 

C Filterable/Condensible Particulate Matter

C Toxic Metals - Arsenic, Chromium, and Lead

C Particulate Matter/Phenol/Total Organic Carbon

C Formaldehyde

C Ammonia

C Methanol

AirNova, Inc. was responsible for the performance of all on-site sampling and for the submittal of

this final test report presenting the test results and detailing all the sampling and analytical methods

employed.

 A description of the sources which were evaluated, a complete summary of the emission test

results, the sampling methodologies that were utilized and the quality control/quality assurance

procedures implemented in the performance of the test program are provided herein. Any questions

pertaining to the information provided herein may be addressed to:

Mark D. Daly

AirNova, Inc.

5845 Clayton Avenue

Pennsauken, New Jersey 08109

Phone: (856) 486-1500

Fax: (856) 486-9896

E-mail: daly@airnova.com
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2.0 Source Information and Description

The CertainTeed Corporation facility manufactures wool fiberglass insulation products for both the

commerical and residential markets. The facility operates two (2) manufacturing lines for this purpose

which are identified as the M1 and M2 Lines. Each manufacturing line consists of a glass melting furnace

which is fired by natural gas. The molten glass exits the furnace through the forehearth to the forming

section where the glass fibers are spun through the action of a series of rotary spinners. An organic

thermosetting binder is added at this time for the purpose of bonding the fibers together to form a

continuous mat. The resulting mat is conveyed through a natural gas fired curing oven and subsequently

through a cooling section. Asphalt adhesive and backing material is then added before the mat is cut into

bats, trimmed and packaged.

Emissions resulting from the two glass melting furnaces (M1 and M2) are directed to a common

Dry Electrostatic Precipitator (Dry ESP). The outlet of the Dry ESP is vented directly to the atmosphere

through a dedicated exhaust stack.

Emissions from the M1 forming section, curing oven and cooling section are directed to the M1

Wet ESP. The M1 adhesive application section is exhausted to the M2A Wet ESP for emission control.

Both the M1 Wet ESP and M2A Wet ESP outlets are exhausted to atmosphere through the common

stack.

Emissions from zone 2 and zone 3 of the M2 forming section are directed to the M2 Wet ESP.

The M2A Wet ESP is utilized for control of emissions resulting from zone 1 of the M2 forming section, the

M2 curing oven, cooling section and asphalt application section. Both the M2 Wet ESP and the M2A Wet

ESP are exhausted to atmosphere through the common stack.

Process flow diagrams for the M1 and M2 manufacturing lines are provided on the following page.
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Figure 2-1

CertainTeed Corporation

Process Flow Diagram
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3.0 Test Results Summary

A complete summary of test results for this emission evaluation test program has been provided

in tabular format. The list of tables which follows indicates the order in which the summary tables have

been provided. 

CertainTeed Corporation

Dry Electrostatic Precipitator and 

Common Outlet Exhaust Stack

Emission Evaluation Test Program

Summary of Test Results Tables

Table No. Description Page No.

3-1 Dry Electrostatic Precipitator - Particulate Matter Test Results

Summary

5

3-2 Dry Electrostatic Precipitator - Toxic Metals, NOx and SO2 Test Results

Summary

6

3-3 Common Outlet - Volatile Organic Compounds and Formaldehyde Test

Results Summary

7

3-4 Common Outlet - Ammonia and Methanol Test Results Summary 8

3-5 Common Outlet - Particulate Matter, Phenol, and Total Organic Carbon

Test Results Summary

9
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Table 3-1

CertainTeed Corporation

Dry Electrostatic Precipitator

Emission Evaluation Test Program

Particulate Matter

Test Results Summary

Run No. 1 2 3 Average

Date 12/03/04 12/03/04 12/03/04

Test Period 1128-1332 1429-1640 1744-1950

Stack Gas Characteristics

Temperature (F) 519 522 523 521

Moisture Content (%) 29.8 30.1 29.1 29.7

Velocity (fps) 45.7 45.8 45.7 45.7

Flow Rate (ACFM) 30,995 31,023 30,980 30,999

Flow Rate (DSCFM) 11,600 11,527 11,665 11,597

Oxygen (%-dry) 8.82 8.94 9.21 8.99

Carbon Dioxide (%-dry) 10.15 10.26 10.07 10.16

Filterable Particulate Matter 

Concentration (gr/DSCF) 8.3E-3 1.4E-2 1.1E-2 1.1E-2

Emission Rate (lb/hr) 0.82 1.34 1.09 1.08

Condensible Particulate Matter 

Concentration (gr/DSCF) 6.0E-2 5.7E-3 2.7E-2 3.1E-2

Emission Rate (lb/hr) 6.00 0.57 2.72 3.10

Total Particulate Matter

Concentration (gr/DSCF) 6.8E-2 5.7E-3 3.8E-2 3.7E-2

Emission Rate (lb/hr) 6.82 1.91 3.81 4.18

Standard Conditions 68o

F, 29.92 in. Hg.
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Table 3-2 

CertainTeed Corporation

Dry Electrostatic Precipitator

Emission Evaluation Test Program

Toxic Metals, NOx and SO2

Test Results Summary

Run No. 1 2 3 Average

Date 12/03/04 12/03/04 12/03/04

Test Period 1128-1332 1429-1640 1744-1950

Stack Gas Characteristics

Temperature (F) 525 526 526 526

Moisture Content (%) 30.7 30.8 30.7 30.7

Velocity (fps) 45.7 45.4 45.3 45.5

Flow Rate (ACFM) 30,962 30,764 30,669 30798

Flow Rate (DSCFM) 10,874 10,772 10,812 10819

Oxygen (%-dry) 8.82 8.94 9.21 8.99

Carbon Dioxide (%-dry) 10.15 10.26 10.07 10.16

Toxic Metals

Chromium (lb/hr) 1.5E-3 1.1E-3 1.6E-3 0.0014

Lead (lb/hr) 2.0E-4 2.7E-4 3.5E-4 2.7E-4

Arsenic (lb/hr) 1.8E-5 <1.6E-5 <1.6E-5 <1.8E-5

Nitrogen Oxides (as NO2)

Concentration (ppmV) 237 255 236 243

Emission Rate (lb/hr) 18.38 19.59 18.20 18.72

Sulfur Dioxide

Concentration (ppmV) <0.1 <0.1 <0.1 <0.1

Emission Rate (lb/hr) <0.01 <0.01 <0.01 <0.01

Standard Conditions 68o

F, 29.92 in. Hg.
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Table 3-3

CertainTeed Corporation

Common Outlet Exhaust Stack

Determination of Formaldehyde and Volatile Organic Compounds

Emission Evaluation Test Program

Test Results Summary

Run No. 1 2 3 Average

Date 12/02/04 12/02/04 12/02/04

Test Period 0952-1115 1321-1446 1723-1838

Stack Gas Characteristics

Temperature (O

F) 102 104 104 103

Moisture Content (%) 7.5 7.2 7.2 7.3

Velocity (FPS) 57.9 58.1 58.4 58.1

Flow Rate (ACFM) 272,867 273,731 275,080 273,893

Flow Rate (DSCFM) 226,209 226,762 227,914 226,962

Oxygen (%) 19.80 19.80 19.77 19.79

Carbon Dioxide (%) 0.60 0.59 0.59 0.59

Formaldehyde Emissions

Concentration (ppmV) 3.2 3.3 2.9 3.1

Emission Rate (lb/hr) 3.37 3.54 3.04 3.32

Volatile Organic Compounds (as methane)

Concentration (ppmV) 26 27 26 26

Emission Rate (lb/hr) 14.65 15.31 14.72 14.89

Standard Conditions 68o

F, 29.92 in. Hg.
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Table 3-4

CertainTeed Corporation

Common Outlet Exhaust Stack

Determination of Ammonia and Methanol

Emission Evaluation Test Program

Test Results Summary

Run No. 1 2 3 Average

Date 12/02/04 12/02/04 12/02/04

Test Period 0805-0935 1133-1300 1501-1629

Stack Gas Characteristics

Temperature (O

F) 105 105 105 105

Moisture Content (%) 7.9 7.7 7.4 7.7

Velocity (FPS) 57.5 57.4 57.4 57.4

Flow Rate (ACFM) 271,159 270,558 270,671 270,796

Flow Rate (DSCFM) 222,727 222,563 223,305 222,865

Oxygen (%) 19.79 19.80 19.74 19.78

Carbon Dioxide (%) 0.61 0.60 0.59 0.60

Ammonia Emissions

Concentration (ppmV) 131 135 136 134

Emission Rate (lb/hr) 77.3 79.4 79.9 78.9

Methanol Emissions 

Concentration (ppmV) 11 4 9 8

Emission Rate (lb/hr) 12.2 4.9 9.9 9.0

Standard Conditions 68o

F, 29.92 in. Hg.
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Table 3-5

CertainTeed Corporation

Common Outlet Exhaust Stack

Determination of Particulate Matter, Phenol, and Total Organic Carbon

Emission Evaluation Test Program

Test Results Summary

Run No. 1 2 3 Average

Date 12/02/04 12/02/04 12/02/04

Test Period 0952-1115 1321-1446 1723-1838

Stack Gas Characteristics

Temperature (O

F) 105 105 105 105

Moisture Content (%) 7.8 7.4 7.2 7.5

Velocity (FPS) 57.9 57.5 57.8 57.7

Flow Rate (ACFM) 272,874 271,084 272,193 272,050

Flow Rate (DSCFM) 223,866 223,873 225,155 224,298

Oxygen (%) 19.80 19.80 19.77 19.79

Carbon Dioxide (%) 0.60 0.59 0.59 0.59

Particulate Matter

Concentration (gr/DSCF) 1.3E-3 2.5E-3 1.3E-3 1.7E-3

Emission Rate (lb/hr) 2.47 4.82 2.57 3.29

Phenol

Concentration (ppmV) 7.3 7.6 5.4 6.8

Emission Rate (lb/hr) 23.9 25.1 17.9 22.3

Total Organic Carbon

Concentration (mg/DSCM) 38.1 26.7 28.3 31.0

Emission Rate (lb/hr) 32.0 22.4 23.9 26.1

Standard Conditions 68o

F, 29.92 in. Hg.
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4.0 Sampling and Analytical Methodologies

The emission test program was conducted in determination of the following parameters utilizing

the methodology specified below:

Table 4-1

CertainTeed Corporation

Wool Fiberglass Manufacturing Facility

Test Methodology Summary

Emission Parameter Sampling and Analytical

Methodology

Test Location

Volumetric Flow Rate EPA Reference Methods 1 and 2 Common Stack/Dry EP

Oxygen/Carbon Dioxide EPA Reference Method 3A Common Stack/Dry EP

Moisture Content EPA Reference Method 4 Common Stack/Dry EP

Filterable and Condensible

Particulate Matter

EPA Reference Method 5/202 Dry EP

Chromium, Lead, Arsenic EPA Reference Method 29 Dry EP

Nitrogen Oxides EPA Reference Method 7E Dry EP

Sulfur Dioxide EPA Reference Method 6C Dry EP

Formaldehyde EPA Reference Method 316 Common Stack

Particulate Matter/Phenol/Total

Organic Carbon

EPA Reference Method 5E Common Stack

Ammonia EPA Reference Method 206 Common Stack

Methanol EPA Reference Method 308 Common Stack

Volatile Organic Compounds EPA Reference Method 18/25A Common Stack

4.1 Cyclonic Flow Determination

The absence of cyclonic flow was demonstrated at each sampling location according to Section

11.4 of EPA Reference Method 1. An S-type pitot was connected to a manometer. The pitot tube was

placed in such a position that the openings of the pitot tube were perpendicular to the stack gas flow. An

angle finder was placed on the pitot tube which was rotated until a reading of zero (0) was obtained. The

'yaw' angle was then recorded.
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4.2 Volumetric Flow Rate Determination

Traverses for volumetric flow rate at each location were determined by using EPA Reference

Methods 1 and 2. An S-type pitot tube attached to an inclined manometer was used to measure gas

stream pressure differentials at the designated traverse points identified for each test location. A Type-K

thermocouple attached to a digital temperature readout was used to measure gas stream temperatures

at each of the designated traverse points for both of the test locations. A baseline coefficient of 0.84 was

assigned to the pitot tube upon a visual inspection which meets the criteria of Section 5.0 of EPA

Reference Method 2.

Sampling was performed at the Common Stack test location which is situated at >2.0 duct

diameters upstream and 6.0 duct diameters downstream from the nearest flow disturbances. Four (4)

sample ports are situated at 90° separation. The stack diameter at this location is 120 inches. A total

of sixteen (16) traverse points (4 points per port) were utilized for all volumetric flowrate determinations.

The traverse point locations were as follows:

Table 4-2

CertainTeed Corporation

Common Outlet Exhaust Stack

Traverse Point Locations

Traverse Point % of Diameter Location (in)

1 3.2 3.8

2 10.5 12.6

3 19.4 23.3

4 32.3 38.8

Sampling was performed at the Dry EP outlet in a vertical section of exhaust duct which is 45.5

inches in diameter. Two test ports located at 6.7 duct diameters downstream and 1.2 duct diameters

upstream from the nearest flow disturbances were utilized for all sampling and velocity traverses. A total

of twenty four (24) traverse points were utilized for all volumetric flowrate determinations. The traverse

point locations were as follows:
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Table 4-3

CertainTeed Corporation

Dry ESP

Traverse Point Locations

Traverse Point % of Diameter Location (in)

1 2.1 1.0 *

2 6.7 3.0

3 11.8 5.3

4 17.7 8.0

5 25.0 11.3

6 35.6 16.0

7 64.4 29.0

8 75.0 33.8

9 82.3 37.0

10 88.2 39.7

11 93.9 42.0

12 97.9 44.0 *

* Relocated in accordance with EPA Reference Method 1, Section 11.3.1.4.

4.3 Moisture Content

Moisture content determinations were performed at each sampling location in accordance with
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EPA Reference Method 4, Section 2.2.2. Determinations conducted by EPA Reference Method 4 utilized

large capacity impingers and collected a minimum volume of 30 DSCF.

4.4 Gaseous Emissions Sampling

An extractive sampling system was used to continuously determine CO2, O2, NOX, SO2, and VOC

concentrations. A representative sample of the flue gas was extracted through a heated (225°) stainless

steel probe and filter assembly, and transported via a heat-traced Teflon sample line through a heated filter

and a Teflon lined diaphragm sample pump to a condensation removal trap located in the mobile

laboratory. The condensation trap was cooled to approximately 37°F. The sample exited the trap free of

moisture and particulates. The sample was then introduced into a constant pressure manifold

constructed of stainless steel and Teflon for metered distribution to the respective analyzers.

4.4.1. Carbon Dioxide and Oxygen

The carbon dioxide and oxygen concentrations in the stack gases were determined by EPA

Reference Method 3A. The sampling system was the same as described above. Oxygen concentrations

were determined using a paramagnetic oxygen analyzer. The oxygen analyzer was operated in the 0-25%

range. A non-dispersive infrared analyzer was utilized to measure carbon dioxide concentrations. The

carbon dioxide analyzer was operated in the 0-15% range. Calibration gases were as follows: nitrogen,

and two (2) upscale span gases of CO2/O2 in nitrogen. The upscale span gases were approximately 45-

55% and 80-95% of span. A zero and midpoint bias calibration was performed both before and after each

test run from the sample probe. Carbon dioxide and oxygen samples were collected simultaneously with

all sampling events. Output signals from the analyzers were stored and processed via a PC based DAS

as well as a strip chart recorder.

4.4.2. Volatile Organic Compounds

VOC emissions were determined by directing a portion of the sample into a total

hydrocarbon analyzer equipped with a flame ionization detector (FID). With the total hydrocarbon analyzer,

sample gas is transported to the FID via the sampling system described in section 4.3, with the exception
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that the sample gas which entered the FID bypassed the condensation trap. Once introduced into the FID,

all hydrocarbon species present are ionized simultaneously to produce the signal output. The THC-FID was

calibrated with certified NIST traceable methane calibration gases. Three (3) calibration gases of 25-35%,

45-55% and 80-95% of span, as well as a zero air (zero gas) were utilized for instrument calibration

procedures. A zero and midpoint bias calibration was performed for the FID both before and after each

test run. The THC-FID was operated in the 0-100 ppmV range. Output signals from the THC-FID were

stored and processed by a PC based DAS system as well as a strip chart recorder.

4.4.3 Sulfur Dioxide

Sulfur dioxide concentrations were determined in accordance with EPA Reference Method

6C utilizing a UV photometric analyzer. The analyzer is comprised of a single ultraviolet source, a chopper

wheel containing two interference filters, a beam splitter, one measuring cell, one reference cell and two

matched photodetectors. During SO2 measurement, two wavelengths are used - one which is absorbed

by SO2 is used for the measuring wavelength (285 nm) and one which is not absorbed by SO2 or other

components normally in the gas sample stream is used as a reference wavelength (585nm). The sample

flows through the measuring cell while the reference cell contains only non-absorbing gases. As the

chopper wheel rotates, a flash of radiation passes through the measuring filter to the beam splitter. After

a brief period, a flash of radiation passes through the reference filter to reference filter to the beam

splitter. These flashes of measuring and reference radiation continue at a nominal frequency of 52 times

per second per filter. The beam splitter directs half the radiation through the measuring cell and half

through the reference cell to the two detectors which develop electrical signals proportional to the amount

of radiation that impinged on the detectors. The detector signals are demultiplexed into two measuring

signals and two reference signals. The reference signals are used to automatically control the gain of each

detector to independently compensate each path for optical contamination. The detector signal developed

from the measuring wavelength radiation that passes through the reference cell is used to control the

current to the ultraviolet source. The two detector signals developed from the reference wavelength
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radiation that pass through the measuring and reference cell are used to produce an analyzer output

signal that is proportional to the SO2 concentration in the measuring cell.

The SO2 analyzer was calibrated prior to the start of sampling with NIST traceable,

Protocol grade calibration gases. Calibration gases were as follows: nitrogen, and two (2) upscale span

gases of approximately 45-55% and 80-95% of span. The analyzer was operated in the 0-100 ppmV

range. A sampling system bias check was performed prior to the first test run by introducing the zero gas

and the mid-level span gas at the sample probe/sample line interface. The sampling system bias check

was repeated after each test run to determine the instrument zero and calibration drift.

4.4.4 Nitrogen Oxides

Nitrogen oxides concentrations were determined by EPA Reference Method 7E. The

principle of this method is to continuously extract a gaseous sample of flue gas and introduce a portion

of this sample into a chemiluminescent analyzer for determination of concentration. The principle of the

analyzer is based on the following reaction:

NO + O3 --> NO2 + O2 + a photon 

The photons emitted by the reaction are measured by a photomultiplier tube. The

photomultiplier signal is proportional to the number of NO molecules; therefore, the photomultiplier signal

is recorded as the concentration for NO. The sample flowrate is carefully controlled. NOx is comprised

of NO and NO2. NO2 present in the sample gas is converted into NO prior to entering the reaction

chamber by a NO2 to NO converter. The NO2 to NO converter breaks one (1) of the two (2) nitrogenoxygen bonds by passing the sample gas through capillary tubing into an electronically controlled, heated

catalytic converter. A converter efficiency check was performed prior to the start of the program in

accordance with Section 5.6.1 of EPA Method 20. Calibration gases were 45-55% and 80-95% of span

plus N2 (zero gas). A zero and midpoint bias calibration were performed from the sample probe both

before and after each test run. All calibrations were conducted in accordance with EPA Reference Method

20. Output signals were stored and processed by a PC based DAS system as well as a strip chart
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AirNova, Inc. 16

recorder. The analyzer was operated in the 0-500 ppmV range.

4.5 Filterable/Condensible Particulate Matter Determination

Filterable particulate emissions were determined as specified in EPA Reference Method 5 by

isokinetically extracting particles from the stack gas and gravimetrically determining the amount collected

in the nozzle, probe, filter holder and filter (front half fraction). Condensible particulate emissions were

determined as specified in EPA Reference Method 202 by gravimetrically determining the amount of

particles collected in the series of four (4) impingers (back half fraction). The volume of liquid collected in

the impingers was also measured gravimetrically to determine the moisture content of the gas stream.

Flue gas parameters were also recorded during the test at each sampling point.

The sample train consists of a heated borosilicate glass probe maintained at 250°F ± 25°F

equipped with a stainless steel button hook nozzle and attached thermocouple and pitot tube. After the

probe, the sample gas passes through a heated glass fiber filter maintained at a temperature of 250°F

± 25°F. The filter was followed by a series of four (4) impingers, as mentioned above, with the first and

second impingers initially containing 100 ml of distilled water each. The third impinger was initially empty

and the fourth contained a known quantity of silica gel. The impingers were followed by a pump, dry gas

meter and calibrated orifice. 

Upon completion of each test run, a leak check of the sampling train was performed at the highest

vacuum encountered during the test run. Following the leak check, the sampling train was disassembled

and the sample fractions were recovered. The front half of the sample train (nozzle, probe and the front

half of the sample train) was initially rinsed with distilled water, then brushed and rinsed three (3) times

with acetone. The washes were placed in separate high density polyethylene containers. The glass fiber

filter was placed in a clean, dry petri dish. The back half of the sample train (series of four (4) impingers)

was measured for volume increase and placed in an amber glass sample jar. The impingers were then

rinsed with deionized water and MeCl2 and the washes retained for analysis. 

Front half filterable particulate was determined gravimetrically by EPA Reference Method 5. The
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procedure which was employed involved the following steps.

1. Transfer the filter and any loose particles from the filter holder to a tared weighing dish. Oven

dry at 250°F and desiccate to a constant weight. Record results to the nearest 0.1 mg.

2. Measure the volume of acetone and water used to rinse the nozzle, probe and front half of the

filter holder. Evaporate each wash at 70o

F and 1 atmosphere in separate tared Teflon

baggies. Heat each Teflon baggie to 220-230°

F, desiccate at room temperature and weigh

to a constant weight. After adjusting for blank contamination, report results to the nearest

0.1 mg.

3. The total particulate matter collected is the sum of the weights obtained for (1) and (2).

Back half condensible particulate was analyzed in accordance with EPA Reference Method 202.

Wash/catch fractions were extracted with MeCl2. The solvent extractant and aqueous extracts were

separated and dried to completeness in Teflon baggies. Each fraction was then weighted to a constant

weight to determine the mass of organic and inorganic condensible PM.

4.6 Metals - Chromium, Lead, and Arsenic

Toxic metals in the exhaust gases were determined isokinetically according to the procedures

outlined in EPA Reference Method 29, "Methodology for the Determination of Metal Emissions in Exhaust

Gases from Hazardous Waste Incinerator Processes".

Metals sampling occurred during 2-hour sampling events with each event collecting a minimum

volume of 60 DSCF. The sampling train consisted of the following components:

C Quartz glass sample nozzle and probe

C Heated glass quartz fiber filter

C A modified Greenburg Smith impinger containing

 100 ml of a 5% HNO3/10% H2O2

C A Greenburg-Smith impinger containing 100 ml 5% HNO3/10% H2O2

C A Greenburg-Smith impinger initially dry

C An impinger containing approximately 225 g of silica gel desiccant

C Dry gas meter equipped with inlet and outlet thermocouples

The sample was extracted from the exhaust stream using a vane-type vacuum pump. Isokinetic

sampling conditions were maintained through the use of a type "S" pitot tube to monitor the exhaust gas

stream pressure differentials. A type "K" thermocouple was utilized to determine the exhaust gas

temperature.
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At the completion of sampling, the probe liner, nozzle, and front half of the filter housing were

rinsed and brushed with a 0.1N nitric acid reagent and the washings retained for analysis. The quartz filter

was removed from the filter holder and placed in a petri dish and sealed. The contents of impingers 1, 2,

and 3 were measured for volume increase and placed in a separate container along with 0.1N nitric acid

washings of the impingers and back half of the filter housing. The silica gel was recovered from the last

impinger and placed in a sealed container for weight gain determination.

Prior to analysis, the collected front and back half liquid sample volumes were reduced to 30 ml

and 25 ml respectively.

4.7 Particulate Matter/Phenol/Total Organic Carbon

Particulate matter, Phenol, and Total Organic Carbon (TOC) emissions were determined in

accordance with EPA Reference Method 5E, “Determination of Particulate Emissions from the Wool

Fiberglass Insulation Manufacturing Industry”. Prior to sampling, the sample train was leak checked at 15

inches Hg vacuum to ensure that all sample train components were leak free. During sampling, gas

samples were isokinetically extracted from the exhaust stack and passed through a quartz glass nozzle,

a glass lined probe and a quartz fiber filter, all maintained at a temperature of 250o

F or less, but

sufficiently high to prevent condensation on the glass fiber filter. The gas sample then passed through an

impinger train consisting of four (4) glass impingers immersed in an ice bath. The arrangement of the

impingers was as follows: 

1st: Modified Greenburg-Smith, containing 100 ml of 0.1N NaOH.

2nd: Greenburg-Smith containing 100 ml of 0.1N NaOH.

3rd: Modified Greenburg-Smith initially dry

4th: Modified Greenburg-Smith containing approximately 350 g of silica gel for final

drying of the gas sample

The sample gas volume was measured by passing it through a calibrated dry gas meter. An S-type

pitot tube was attached to the sample probe to monitor the stack gas velocity in order to maintain

isokinetic sampling conditions. In addition, a type K thermocouple was attached to measure the exhaust

gas temperature. Following each test run, the sample train was leak checked at the highest vacuum
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recorded during the run. 

After each run, the probe, nozzle and all connecting glassware ahead of the filter were brushed

and rinsed with acetone. The washings were retained in a high density polyethylene container. The quartz

fiber filter was placed in it's original petri dish. The impinger contents were recovered and measured for

moisture gain. The impinger contents were then captured into a glass amber jar. The silica gel was placed

in its original pre-weighed polyethylene container. Impingers 1,2, and 3 were then rinsed three (3) times

each with deionized water and the washes were placed into a glass amber jar. 

After receiving and logging the samples at the AirNova, Inc. laboratory, the glass fiber filters were

oven dried for 2 - 3 hours at the average temperature maintained during the corresponding test run,

desiccated for 2 - 3 more hours and then reanalyzed for a final weight determination. The acetone

samples were evaporated at room temperature and pressure in tared beakers, desiccated for 24 hours

and also reanalyzed for a final weight determination. Laboratory data was then inputed to a spreadsheet

software program to calculate PM concentration (grains/dscf) and mass emissions (lb/hr).

TOC emissions were quantified by converting organic carbon in the sample to carbon dioxide by

catalytic combustion or wet chemical oxidation. The carbon dioxide formed was measured directly by an

infrared detector or converted to methane and measured by a flame ionization detector. The amount of

carbon dioxide or methane is directly proportional to the concentration of carbonaceous material in the

sample.

Phenol emissions were quantified in the 0.1N NaOH solution by being acidified and analyzed by

using a High Performance Liquid Chromatograph (HPLC) equipped with an ultraviolet detector.

4.8 Formaldehyde

Formaldehyde emission determinations were performed isokinetically utilizing EPA Reference

Method 316. “Sampling and Analysis for Formaldehyde Emissions from Stationary Sources in the Mineral

and Wool Fiberglass Industry”. Samples were withdrawn from the exhaust stack through a stainless steel

nozzle and a heated, glass-lined probe. The gas stream then enters an impinger train. The first impinger,
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a modified Greenburg-Smith, contained 100 ml of ASTM Type 1 water and was followed by a GreenburgSmith impinger containing 100 ml of ASTM Type 1 water. A third impinger, a modified Greenburg-Smith

design was initially empty. The last impinger contained a pre-weighed quantity of silica gel. The sample

probe was heated to 248±25°F. Sampling was conducted isokinetically for a period of 60 minutes

collecting a sample volume of approximately 50 DSCF.

At the completion of sampling, the nozzle, probe and all connecting glassware ahead of the

impingers were brushed and rinsed with water. The washings were retained in an amber glass sample

jar with a Teflon lined lid.

All impingers were measured for any increase in volume and retained in the same container along

with water rinses of the impingers and all connecting glassware. The silica gel was measured

gravimetrically for any increase in moisture content. The samples were analyzed by the Pararosaniline

spectrophotometric technique described in the method.

4.9 Ammonia

Emissions of ammonia were determined isokinetically using EPA Reference Method 206. The

sample train consisted of the following apparatus connected in series:

C In-stack glass fiber filter and quartz glass nozzle

C Heated glass probe 

C Two (2) Greenburg-Smith impingers each containing 100 ml of 0.1 N H2SO4

C A modified Greenburg-Smith impinger initially empty

C A modified Greenburg-Smith impinger containing 225 g of silica gel desiccant

C Vane type pump

C Dry gas meter equipped with thermocouples

An S-type pitot tube attached to the sample probe monitored the exhaust gas stream pressure

differentials in order to maintain isokinetic sampling conditions. A K-type thermocouple was used to

measure the exhaust gas temperature.

Sampling was conducted during three (3) 60 minute events each collecting a minimum sample

volume of 30 DSCF. Prior to the start of sampling, leak checks were conducted at 15 in. Hg vacuum to

insure that all connections were leak free.
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At the completion of sampling, the sampling train was post run leak checked and then

disassembled and the sample fractions recovered. The nozzle and front half of the filter holder were rinsed

and brushed with distilled water and the rinsings were retained in a polyethylene sample jar. The glass

fiber filter was removed and retained in a glass petri dish . All sample exposed areas of the front half of

the sampling train (probe and back of the filter holder) were brushed and washed with 0.1 N H2SO4 and

placed in a polyethylene container. The contents of Impinger No.'s 1 and 2 were measured for volume

increase, rinsed with deionized distilled water to a volume not exceeding 230 ml and placed in a 250 ml

polyethylene container. The contents of Impinger No. 3 were measured for volume increase, rinsed with

deionized distilled water to a volume not exceeding 230 ml and placed in a 250 ml polyethylene container

The silica gel desiccant was removed from the last impinger and placed in a pretared polyethylene

container. The samples were refrigerated then transported to the AirNova, Inc. facility for subsequent

analysis.

The silica gel samples were reweighed to determine moisture gain. All collected sample fractions

were analyzed in accordance with EPA Reference Method 206 utilizing an HPLC equipped with a

nonsuppressed conductivity detector. 

4.10 Methanol

 Methanol emissions were determined in accordance with EPA Reference Method 308,

“Procedure for the Determination of Methanol Emissions from Stationary Sources”. Utilizing this method,

a gas sample is extracted from a centroid point inside the stack. The methanol is collected in deionized

water and absorbed on silica gel tubes. Specifically, two (2) midget impingers connected in series were

filled with 15 ml of deionized distilled water, and a silica gel tube was attached to the impinger as a drying

agent.

Stainless steel and teflon tubing was utilized as the sampling probe before the midget impinger

and after the silica gel tube into the dry gas volume meter. The train was pre-leak checked at 10 inches

of mercury vacuum to ensure that all components of the sampling train were leak free. A post-leak check
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was conducted at the end each test run at 10 inches of vacuum. 

Following the end of each test run and the post-leak check, the sampling train was disassembled,

and the midget impinger filled with deionized water was captured in a 45 ml amber vial. Three (3)

deionized water rinses were implemented for the midget impinger and placed in the same sample vial.

Analysis of the sample fractions obtained by aqueous impingement and silica gel tube absorption

involved the utilization of an 8610 SRI Gas Chromatograph equipped with a flame ionization detector. 

5.0 Quality Assurance/Quality Control Procedures

All of the source sampling and analytical procedures were performed in accordance with the US
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EPA's 'Good Laboratory Practice' guidelines. AirNova, Inc. followed the requirements of the individual test

methods to ensure the precision and accuracy of the source testing procedures. In addition, AirNova, Inc.

followed the procedures provided in the 'Quality Assurance Handbook for Air Pollution Measurement

Systems, Volume III, Stationary Sources'. Sampling equipment utilized in the test program was calibrated

prior to the test performance. The following procedures were utilized.

5.1 S-Type Pitot Tubes

The S-type pitot tubes were visually inspected to verify dimension requirements. Pitot tubes

meeting requirements were assigned a pitot tube coefficient of 0.84. Pitot tubes which did not meet the

requirements were not utilized.

5.2 Dry Gas Meters and Orifice

All dry gas meters used in the field were calibrated against a transfer standard dry gas meter that

is maintained in AirNova's calibration data. The transfer standard gas meter is calibrated annually and

certified against an NIST traceable Bell-type Prover which operates by liquid displacement.

Field dry gas meters and orifice meters are calibrated at two month intervals at the following

orifice meter settings:

C 0.5 in. H2O

C 1.0 in. H2O

C 1.5 in. H2O

C 2.0 in. H2O

C 3.0 in. H2O

C 4.0 in. H2O

The initial and final volume readings and temperature readings were recorded for the dry

gas meter and the secondary standard test meter at each orifice meter setting. A dry gas meter

correction factor (DGMCF) was calculated for each setting and the average DGMCF was recorded.

All calibration documentation is stored in a designated filing cabinet for future reference. All repair

and maintenance documentation for each meter is stored in files that provide a history of each meter and

aid in our preventative maintenance program.
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AirNova, Inc. also participates in the EPA Method 5 dry Gas Meter Audit Program.

5.3 Nozzles

Probe nozzles selected for isokinetic sampling were calibrated according to section 3.4.2 of the

"Quality Assurance Handbook for Air Pollution Measurement Systems: Volume III" Upon receipt, the inner

diameter of each nozzle was measured across three (3) distinct diameters with a micrometer caliper.

The calibrated nozzle diameter is the average of these measurements. Each nozzle is identified uniquely

and its calibrated diameter is checked prior to use.

5.4 Thermocouples

Thermocouples and thermometers utilized in the sampling program were calibrated according

to section 3.4.2 of the "Quality Assurance for Air Pollution Measurement Systems: Volume III" every two

months. The calibration method includes comparing each field thermometer and thermocouple at

different temperatures to an ASTM certified mercury-in-glass thermometer. The temperatures must

agree within the tolerances mentioned for the type of sampling equipment being calibrated. All the

calibration data is stored in a designated filing cabinet for future reference.

1. Stack Gas and Filter Housing Thermocouples and Thermometers

Three temperatures are measured and extrapolated over the range of temperatures 

encountered in field operations. The three temperatures used for calibration are:

1. Ice bath

2. Boiling point of water

3. Boiling point of cooking oil (or equivalent in solid salt bath)

2. Impinger Thermometers and Thermocouples

Two temperatures are required to calibrate:

1. Ice bath

2. Stabilized room temperature

3. Dry Gas Thermometers

Two temperatures are required to calibrate:

1. Stabilized hot water bath at approximately 104 - 122°F (40 - 50°C)

2. Stabilized room temperature

5.5 Labels

All samples collected as part of the sampling program (silica gel desiccant samples) were affixed
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with labels which identify the following: 1) Project No., 2) Date, 3) Type of sample, 4) Run No., 5) Sample

location, and 6) Sample fraction.

5.6 Chain-of-Custody Documentation

Chain-of-custody documentation for all samples was implemented at the completion of sampling

and sample clean-up and was documented until the samples were received by the laboratory for analysis.

5.7 Calibration Gases

C NIST Traceable Protocol 1 grade (±1%) gas standards were utilized for calibration

of the O2, CO2, NOX, SO2, and THC analyzers.