Name: Mary Ann Keon

Title: Environmental Director

Company: Boral Industries

Sign Date: 2/25/2011

Name: Tommy Lotz, Jr.

Title: Project Manager

Company: TRC Environmental

Sign Date: 2/25/2011

Permitted Facility Representative / Date Testing Company Representative / Date

Boral Union Outlet

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.

Wednesday, March 23, 2011 Page 1 of 12
Boral Union Outlet

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Facility Information:

Boral Bricks, Inc.

3895 S. Choctaw Avenue

Union City OK 73090

Contact: Mary Ann Keon

Phone: 770-645-4529

Fax:

Email: maryann.keon@boral.com

Testing Company:

TRC Environmental

108 Yeager Circle

Pelham AL 35124

Contact:Tommy Lotz, Jr.

Phone: 205-358-3203

Fax: 205-358-7492

Email: telotz@TRCsolutions.com

Air Permit Number:

2004-210-O (M-2)

Permitted Source ID/Name:

EU-04 Tunnel Kiln

Permitted Maximum Process Rate:

180,631 TPY

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:

The source is a gas fired tunnel kiln. The gas consists of natural gas (45-55%) and landfill gas (15-55%). Emissions 

are controlled by a dry sorbent injection fabric filter (DIFF)

Industry/SCC/NAIS 327121

Sampling Location Information:

Test Parameter Information:

AFS #: 4001700097 FRS #: 110015563345

SCC / Description 30500311 Industrial Processes - Mineral Products - Brick Manufacture - Curing and Firing: 

Gas-fired Tunnel Kilns 

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

Outlet 54.5 0 0 0 336 222 2 20

Target

Parameter 

Test

Method

Number of

Test Runs

Test Run

Duration

Sample 

Location Points Comments

Outlet % H2O Method 1 - 4 3 64 0

Outlet Flowrate Method 1 - 4 3 64 0

Outlet Hydrogen Chloride Method 26A 3 64 0

Regulation Description Compound Limit Unit

PM 2.98 TPY

HCl 9.99 TPY

HF 9.99 TPY

Wednesday, March 23, 2011 Page 2 of 12
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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.

Outlet Chlorine Method 26A 3 64 0

Outlet Hydrogen Fluoride Method 26A 3 64 0

Outlet Chromium Method 29 3 64 0

Outlet Beryllium Method 29 3 64 0

Outlet Antimony Method 29 3 64 0

Outlet Cadmium Method 29 3 64 0

Outlet Lead Method 29 3 64 0

Outlet Selenium Method 29 3 64 0

Outlet Mercury Method 29 3 64 0

Outlet Manganese Method 29 3 64 0

Outlet Cobalt Method 29 3 64 0

Outlet Nickel Method 29 3 64 0

Filterable 

Particulate

Outlet Method 29 3 64 0

Outlet Arsenic Method 29 3 64 0

Outlet O2 Method 3A O2 3 60 0

Wednesday, March 23, 2011 Page 3 of 12
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Sampling / Stack Data Results Summary

Location Outlet - Method 26A

Average

Run Number M26-1 M26-2 M26-3

Test Date 11/17/2010 11/17/2010 11/17/2010

Run Start Time 10:30:00 AM 1:00:00 PM 2:50:00 PM

Run Finish Time 11:37:00 AM 2:04:00 PM 3:55:00 PM

Net Run Time, minutes 60 60 60

Dry Gas Meter Volume Sampled, dscf 34.422 40.135 41.398 38.652

Moisture Content of Stack Gas, % 7.67 6.98 7.69 7.447

Moisture Saturation at Stack Gas Temperature, % 100.00 100.00 100.00 100.000

Carbon Dioxide, % 4.2 3.9 3.9 4.000

Oxygen, % 16.2 16.4 16.4 16.333

Average Stack Gas Temperature, °F 285.45 278.55 276.00 280.000

Dry Volumetric Flow Rate, dry scfm 12,638.9 15,475.5 15,820.3 14,644.900

Actual Wet Volumetric Flue Gas Flow Rate, acfm 19,430.3 23,396.0 24,018.1 22,281.467

Percent Isokinetic of Sampling Rate, % 98.5 93.8 94.6 95.633

F-Factor, dscfm/MMBtu @ %O2 0 0 0 0.000

Fw 0 0 0 0.000

Fc 0 0 0 0.000

Location Outlet - Method 29

Average

Run Number M29/5-1 M29/5-2 M29/5-3

Test Date 11/17/2010 11/17/2010 11/17/2010

Run Start Time 10:30:00 AM 1:00:00 PM 2:50:00 PM

Run Finish Time 11:30:00 AM 2:04:00 PM 3:55:00 PM

Net Run Time, minutes 60 60 60

Dry Gas Meter Volume Sampled, dscf 34.016 43.722 44.936 40.891

Moisture Content of Stack Gas, % 7.33 9.28 8.19 8.267

Moisture Saturation at Stack Gas Temperature, % 100.00 100.00 100.00 100.000

Carbon Dioxide, % 4.2 3.9 3.9 4.000

Oxygen, % 16.2 16.4 16.4 16.333

Average Stack Gas Temperature, °F 287.25 281.40 278.75 282.467

Dry Volumetric Flow Rate, dry scfm 11,046.9 14,716.3 15,720.5 13,827.900

Actual Wet Volumetric Flue Gas Flow Rate, acfm 16,961.4 22,900.3 24,086.2 21,315.967

Percent Isokinetic of Sampling Rate, % 99.2 95.7 92.1 95.667

F-Factor, dscfm/MMBtu @ %O2 0 0 0 0.000

Fw 0 0 0 0.000

Fc 0 0 0 0.000

Wednesday, March 23, 2011 Page 4 of 12
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2/25/2011

Location Outlet - Method 3A O2

Average

Run Number 1 2 3

Test Date 11/17/2010 11/17/2010 11/17/2010

Run Start Time 10:30:00 AM 1:00:00 PM 2:50:00 PM

Run Finish Time 11:30:00 AM 2:00:00 PM 3:50:00 PM

Carbon Dioxide, % 0 0 0 0.000

Oxygen, % 0 0 0 0.000

Dry Volumetric Flow Rate, dry scfm 0 0 0 0.000

F-Factor, dscfm/MMBtu @ %O2 8710 8710 8710 8,710.000

Moisture, % 0 0 0 0.000

Fuel Type Gas - Natural Gas - 

Natural

Gas - Natural

Fw 10610 10610 10610 10,610.000

Fc 1040 1040 1040 1,040.000

Wednesday, March 23, 2011 Page 5 of 12
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Emissions Summary

Location: Outlet - Method 26A

Compound: Chlorine

Average

RunNumber M26-1 M26-2 M26-3

Mass_mg 0 0 0 0.000

Eg/hr 0.00E+00 0.00E+00 0.00E+00 0.000

Elb/hr 0.00E+00 0.00E+00 0.00E+00 0.000

ppm 0.00E+00 0.00E+00 0.00E+00 0.000

ppm@7%O2 0.00E+00 0.00E+00 0.00E+00 0.000

Compound: Hydrogen Chloride

Average

RunNumber M26-1 M26-2 M26-3

Mass_mg 3.51 4.11 2.76 3.460

Eg/hr 7.73E+01 9.51E+01 6.33E+01 78.567

Elb/hr 1.70E-01 2.10E-01 1.40E-01 0.173

ppm 2.38E+00 2.39E+00 1.55E+00 2.107

ppm@7%O2 7.04E+00 7.38E+00 4.79E+00 6.403

Compound: Hydrogen Fluoride

Average

RunNumber M26-1 M26-2 M26-3

Mass_mg 0.01 0.2 0.02 0.077

Eg/hr 2.20E-01 4.63E+00 4.59E-01 1.770

Elb/hr 4.86E-04 1.02E-02 1.01E-03 0.004

ppm 1.23E-02 2.12E-01 2.05E-02 0.082

ppm@7%O2 3.64E-02 6.55E-01 6.33E-02 0.252

Location: Outlet - Method 29

Compound: Antimony

Average

RunNumber M29/5-1 M29/5-2 M29/5-3

Mass_mg 0.0004 0.0004 0.0004 0.000

Eg/hr 7.79E-03 8.08E-03 8.40E-03 0.008

Elb/hr 1.72E-05 1.78E-05 1.85E-05 0.000

mg/dscm 4.15E-04 3.23E-04 3.14E-04 0.000

mg/dscm@7%O2 1.23E-03 9.98E-04 9.70E-04 0.001

Compound: Arsenic

Average

RunNumber M29/5-1 M29/5-2 M29/5-3

Mass_mg 0.0445 0 0 0.015

Eg/hr 8.67E-01 0.00E+00 0.00E+00 0.289

Elb/hr 1.91E-03 0.00E+00 0.00E+00 0.001

mg/dscm 4.62E-02 0.00E+00 0.00E+00 0.015

mg/dscm@7%O2 1.37E-01 0.00E+00 0.00E+00 0.046

Compound: Beryllium

Average

RunNumber M29/5-1 M29/5-2 M29/5-3

Mass_mg 0.00253 0 0 0.001

Wednesday, March 23, 2011 Page 6 of 12
Boral Union Outlet

2/25/2011

Eg/hr 4.93E-02 0.00E+00 0.00E+00 0.016

Elb/hr 1.09E-04 0.00E+00 0.00E+00 0.000

mg/dscm 2.63E-03 0.00E+00 0.00E+00 0.001

mg/dscm@7%O2 7.78E-03 0.00E+00 0.00E+00 0.003

Compound: Cadmium

Average

RunNumber M29/5-1 M29/5-2 M29/5-3

Mass_mg 0.0002 0.0005 0.00006 0.000

Eg/hr 3.90E-03 1.01E-02 1.26E-03 0.005

Elb/hr 8.59E-06 2.23E-05 2.78E-06 0.000

mg/dscm 2.08E-04 4.04E-04 4.72E-05 0.000

mg/dscm@7%O2 6.15E-04 1.25E-03 1.46E-04 0.001

Compound: Chromium

Average

RunNumber M29/5-1 M29/5-2 M29/5-3

Mass_mg 0.0101 0.005 0.0041 0.006

Eg/hr 1.97E-01 1.01E-01 8.61E-02 0.128

Elb/hr 4.34E-04 2.23E-04 1.90E-04 0.000

mg/dscm 1.05E-02 4.04E-03 3.22E-03 0.006

mg/dscm@7%O2 3.11E-02 1.25E-02 9.95E-03 0.018

Compound: Cobalt

Average

RunNumber M29/5-1 M29/5-2 M29/5-3

Mass_mg 0 0 0 0.000

Eg/hr 0.00E+00 0.00E+00 0.00E+00 0.000

Elb/hr 0.00E+00 0.00E+00 0.00E+00 0.000

mg/dscm 0.00E+00 0.00E+00 0.00E+00 0.000

mg/dscm@7%O2 0.00E+00 0.00E+00 0.00E+00 0.000

Compound: Filterable Particulate

Average

RunNumber M29/5-1 M29/5-2 M29/5-3

Mass_mg 0 3.1 5.8 2.967

Eg/hr 0.00E+00 6.26E+01 1.22E+02 61.533

Elb/hr 0.00E+00 1.38E-01 2.68E-01 0.135

mg/dscm 0.00E+00 2.50E+00 4.56E+00 2.353

mg/dscm@7%O2 0.00E+00 7.72E+00 1.41E+01 7.273

Compound: Lead

Average

RunNumber M29/5-1 M29/5-2 M29/5-3

Mass_mg 0 0.0001 0.0005 0.000

Eg/hr 0.00E+00 2.02E-03 1.05E-02 0.004

Elb/hr 0.00E+00 4.45E-06 2.31E-05 0.000

mg/dscm 0.00E+00 8.08E-05 3.93E-04 0.000

mg/dscm@7%O2 0.00E+00 2.50E-04 1.21E-03 0.000

Compound: Manganese

Average

RunNumber M29/5-1 M29/5-2 M29/5-3

Mass_mg 0.04936 0.0041 0.02333 0.026

Wednesday, March 23, 2011 Page 7 of 12
Boral Union Outlet

2/25/2011

Process Run Data

Eg/hr 9.62E-01 8.28E-02 4.90E-01 0.512

Elb/hr 2.12E-03 1.83E-04 1.08E-03 0.001

mg/dscm 5.13E-02 3.31E-03 1.83E-02 0.024

mg/dscm@7%O2 1.52E-01 1.02E-02 5.65E-02 0.073

Compound: Mercury

Average

RunNumber M29/5-1 M29/5-2 M29/5-3

Mass_mg 0.0005 0.0007 0.0007 0.001

Eg/hr 9.74E-03 1.41E-02 1.47E-02 0.013

Elb/hr 2.15E-05 3.12E-05 3.24E-05 0.000

mg/dscm 5.19E-04 5.65E-04 5.50E-04 0.001

mg/dscm@7%O2 1.53E-03 1.75E-03 1.70E-03 0.002

Compound: Nickel

Average

RunNumber M29/5-1 M29/5-2 M29/5-3

Mass_mg 0.013 0.0054 0.0038 0.007

Eg/hr 2.53E-01 1.09E-01 7.98E-02 0.147

Elb/hr 5.58E-04 2.40E-04 1.76E-04 0.000

mg/dscm 1.35E-02 4.36E-03 2.99E-03 0.007

mg/dscm@7%O2 3.99E-02 1.35E-02 9.24E-03 0.021

Compound: Selenium

Average

RunNumber M29/5-1 M29/5-2 M29/5-3

Mass_mg 0.0048 0.0059 0.0066 0.006

Eg/hr 9.35E-02 1.19E-01 1.39E-01 0.117

Elb/hr 2.06E-04 2.63E-04 3.05E-04 0.000

mg/dscm 4.98E-03 4.77E-03 5.19E-03 0.005

mg/dscm@7%O2 1.47E-02 1.47E-02 1.60E-02 0.015

Wednesday, March 23, 2011 Page 8 of 12
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Process Run Data

APCD Run Data

Process Lab Run Data

Run Name Value UOM Comments

Target

Value

1 Brick Produced 11.88 Tons/hr 11.8

2 Brick Produced 11.88 Tons/hr 11.8

3 Brick Produced 11.88 Tons/hr 11.8

1 Lime Feed Rate 24.6 lbs/hr 24

2 Lime Feed Rate 24.6 lbs/hr 24

3 Lime Feed Rate 24.6 lbs/hr 24

Run Name Value UOM Comments

Target

Value

1 DRY LIMESTONE INJECTION 0 0

1 BAGHOUSE 0 0

Wednesday, March 23, 2011 Page 9 of 12
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Sampling / Stack Data Results Detail

Location Outlet - Method 26A

Average

Run Number M26-1 M26-2 M26-3

Test Date 11/17/2010 11/17/2010 11/17/2010

Run Start Time 10:30:00 AM 1:00:00 PM 2:50:00 PM

Run Finish Time 11:37:00 AM 2:04:00 PM 3:55:00 PM

Net Traversing Points 21 21 21

Net Run Time, minutes 60 60 60

Nozzle Diameter, inches 0.37 0.37 0.37 0.370

Pitot Tube Coefficient 0.84 0.84 0.84 0.840

Dry Gas Meter Calibration Factor 1.0099 1.0099 1.0099 1.010

Barometric Pressure, inches of Mercury 29.77 29.77 29.77 29.770

Average Orifice Meter Differential, inches H2O 1.07 1.54 1.60 1.403

Dry Gas Meter Volume Sampled, cubic feet 33.807 38.622 39.595 37.341

Average Dry Gas Meter Temperature, °F 62.45 52.50 49.45 54.800

Dry Gas Meter Volume Sampled, dscf 34.422 40.135 41.398 38.652

Total Moisture Liquid collected, g 60.8 64 73.4 66.067

Volume of Water Vapor, standard cubic feet 2.86 3.01 3.45 3.107

Moisture Content of Stack Gas, % 7.67 6.98 7.69 7.447

Moisture Saturation at Stack Gas Temperature, % 100.00 100.00 100.00 100.000

Dry Mole Fraction 0.9233 0.9302 0.9231 0.926

Carbon Dioxide, % 4.2 3.9 3.9 4.000

Oxygen, % 16.2 16.4 16.4 16.333

Carbon Monoxide & Nitrogen, % 79.6 79.7 79.7 79.667

Fuel Factor 1.12 1.15 1.15

Dry Molecular Weight, lb/lb-Mole 29.32 29.28 29.28 29.293

Wet Molecular weight, lb/lb-Mole 28.45 28.49 28.41 28.450

Flue Gas Static Pressure, inches of H2O -0.07 -0.07 -0.07 -0.070

Absolute Flue Gas Pressure, inches of Mercury 29.76 29.76 29.76 29.760

Average Stack Gas Temperature, °F 285.45 278.55 276.00 280.000

Average Velocity Head, inches of H2O 0.088 0.129 0.136 0.118

Average Stack Gas Velocity, feet/second 19.99 24.07 24.71 22.923

Stack Cross-Sectional Area, square feet 16.200 16.200 16.200 16.200

Dry Volumetric Flow Rate, dry scfm 12,638.9 15,475.5 15,820.3 14,644.900

Actual Wet Volumetric Flue Gas Flow Rate, acfm 19,430.3 23,396.0 24,018.1 22,281.467

Percent Isokinetic of Sampling Rate, % 98.5 93.8 94.6 95.633

Percent Excess Air, % 336.5 353.4 353.4 347.767

F-Factor, dscfm/MMBtu @ %O2 0 0 0 0.000

Round Duct Diameter, inches 54.5 54.5 54.5

Rectangular Duct Width, inches 0 0 0

Rectangular Duct Length, inches 0 0 0

Fw 0 0 0 0.000

Fc 0 0 0 0.000

Wednesday, March 23, 2011 Page 10 of 12
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Location Outlet - Method 29

Average

Run Number M29/5-1 M29/5-2 M29/5-3

Test Date 11/17/2010 11/17/2010 11/17/2010

Run Start Time 10:30:00 AM 1:00:00 PM 2:50:00 PM

Run Finish Time 11:30:00 AM 2:04:00 PM 3:55:00 PM

Net Traversing Points 20 20 20

Net Run Time, minutes 60 60 60

Nozzle Diameter, inches 0.392 0.392 0.392 0.392

Pitot Tube Coefficient 0.84 0.84 0.84 0.840

Dry Gas Meter Calibration Factor 0.9826 0.9826 0.9826 0.983

Barometric Pressure, inches of Mercury 29.77 29.77 29.77 29.770

Average Orifice Meter Differential, inches H2O 0.93 1.65 1.80 1.460

Dry Gas Meter Volume Sampled, cubic feet 33.855 42.805 43.700 40.120

Average Dry Gas Meter Temperature, °F 54.95 47.45 44.25 48.883

Dry Gas Meter Volume Sampled, dscf 34.016 43.722 44.936 40.891

Total Moisture Liquid collected, g 57.2 95 85.2 79.133

Volume of Water Vapor, standard cubic feet 2.69 4.47 4.01 3.723

Moisture Content of Stack Gas, % 7.33 9.28 8.19 8.267

Moisture Saturation at Stack Gas Temperature, % 100.00 100.00 100.00 100.000

Dry Mole Fraction 0.9267 0.9072 0.9181 0.917

Carbon Dioxide, % 4.2 3.9 3.9 4.000

Oxygen, % 16.2 16.4 16.4 16.333

Carbon Monoxide & Nitrogen, % 79.6 79.7 79.7 79.667

Fuel Factor 1.12 1.15 1.15

Dry Molecular Weight, lb/lb-Mole 29.32 29.28 29.28 29.293

Wet Molecular weight, lb/lb-Mole 28.49 28.23 28.36 28.360

Flue Gas Static Pressure, inches of H2O -0.07 -0.07 -0.07 -0.070

Absolute Flue Gas Pressure, inches of Mercury 29.76 29.76 29.76 29.760

Average Stack Gas Temperature, °F 287.25 281.40 278.75 282.467

Average Velocity Head, inches of H2O 0.067 0.122 0.136 0.108

Average Stack Gas Velocity, feet/second 17.45 23.56 24.78 21.930

Stack Cross-Sectional Area, square feet 16.200 16.200 16.200 16.200

Dry Volumetric Flow Rate, dry scfm 11,046.9 14,716.3 15,720.5 13,827.900

Actual Wet Volumetric Flue Gas Flow Rate, acfm 16,961.4 22,900.3 24,086.2 21,315.967

Percent Isokinetic of Sampling Rate, % 99.2 95.7 92.1 95.667

Percent Excess Air, % 336.5 353.4 353.4 347.767

F-Factor, dscfm/MMBtu @ %O2 0 0 0 0.000

Round Duct Diameter, inches 54.5 54.5 54.5

Rectangular Duct Width, inches 0 0 0

Rectangular Duct Length, inches 0 0 0

Fw 0 0 0 0.000

Fc 0 0 0 0.000

Wednesday, March 23, 2011 Page 11 of 12
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Location Outlet - Method 3A O2

Average

Run Number 1 2 3

Test Date 11/17/2010 11/17/2010 11/17/2010

Run Start Time 10:30:00 AM 1:00:00 PM 2:50:00 PM

Run Finish Time 11:30:00 AM 2:00:00 PM 3:50:00 PM

Carbon Dioxide, % 0 0 0 0.000

Oxygen, % 0 0 0 0.000

Fuel Factor 0 0 0

Dry Volumetric Flow Rate, dry scfm 0 0 0 0.000

F-Factor, dscfm/MMBtu @ %O2 8710 8710 8710 8,710.000

Moisture, % 0 0 0 0.000

Analyzer Make Servomex Servomex Servomex #Error

Analyzer Model 1440 1440 1440 1,440.000

Analyzer Serial Number #Num!

Operating Range 19.96 19.96 19.96 19.960

Operating Units ppm ppm ppm

No. Readings/Avg. 60 60 60 60.000

Calibration Set 1 1 1 1.000

Calibration Pre Zero Cylinder ID CC207920 CC207920 CC207920

Calibration Pre Zero Cylinder Instrument Response 0 0 0 0.000

Calibration Pre Zero Cylinder Bias 0 0 0 0.000

Calibration Pre Zero Cylinder Drift 0 0 0 0.000

Calibration Pre High Cylinder ID SG9134085B

AL

SG9134085B

AL

SG9134085B

AL

Calibration Pre High Cylinder Instrument Response 9.7 10 9.9 9.867

Calibration Pre High Cylinder Bias -0.5 1 0.5 0.333

Calibration Pre High Cylinder Drift 0 0 0 0.000

Calibration Post Zero Cylinder ID CC207920 CC207920 CC207920

Calibration Post Zero Cylinder Instrument Response 0 0 0 0.000

Calibration Post Zero Cylinder Bias 0 0 0 0.000

Calibration Post Zero Cylinder Drift 0 0 0 0.000

Calibration Post High Cylinder ID SG9134085B

AL

SG9134085B

AL

SG9134085B

AL

Calibration Post High Cylinder Instrument Response 10 9.9 9.8 9.900

Calibration Post High Cylinder Bias 1 0.5 0 0.500

Calibration Post High Cylinder Drift 1.5 0.5 0.5 0.833

Cavg 16.2 16.5 16.4 16.367

Cavg Units ppmvd ppmvd ppmvd

Cgas 16.2132 16.3474 16.4133 16.325

Cgas Units ppmvd ppmvd ppmvd

Fuel Type Gas - Natural Gas - Natural Gas - Natural

Fw 10610 10610 10610 10,610.000

Fc 1040 1040 1040 1,040.000

Cgasw 0 0 0 0.000

Cgasw Units

Wednesday, March 23, 2011 Page 12 of 12