Name: Fred Walsh

Title: Environmental Manager

Company: Mt. Carmel Cogen Inc.

Sign Date: 9/29/2010

Name: Stephen Schell

Title: President

Company: Air Analysis, LLC

Sign Date: 9/29/2010

Permitted Facility Representative / Date Testing Company Representative / Date

Mount Carmel Cogen - ICR

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.

Sunday, January 30, 2011 Page 1 of 12
Mount Carmel Cogen - ICR

9/29/2010

Facility Information:

Foster Wheeler Mt. Carmel Cogen

P.O. Box 409

Marion Heights PA 17832

Contact: Fred Walsh

Phone: 570 373-3999

Fax:

Email: fredwalsh@mtcarmelcogen.com

Testing Company:

Air Analysis, LLC t/a SGF Consulting Services

189 Hausman Road

Lenhartsville PA 19534

Contact: Stephen Schell

Phone: 610 756-3490

Fax: 610 756-3491

Email: sschell@hughes.net

Air Permit Number:

49-00001

Permitted Source ID/Name:

SG-101 Foster Wheeler Mt. Carmel Cogen

Permitted Maximum Process Rate: Max. Normal Operation Process Rate:

623.5 mmBtu/hr

Target Process Test Rate

90% of Maximum Load

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

 process flow diagram:

The Mount Carmel Cogeneration facility typically produces 40 MW of electricity and consists of a 623.5 mmBtu/hr 

Foster Wheeler brand circulating fluidized bed boiler, which utilizes waste anthracite coal as its main fuel. Emissions 

are controlled with limestone addition for sulfulr dioxide emissions control and a Joy Environmental Equipment 

Company fabric filter collector for particulate emissions control. Flue gas emissions are discharged from the fabric 

filter collector through a Howden I.D. Fan rated at 239,036 cfm and then to the atmosphere through a vertical stack.

Industry/SCC/NAIS 221112

Sampling Location Information:

Test Parameter Information:

AFS #: 4209700067 FRS #: 110007026306

SCC / Description 10102018 External Combustion Boilers - Electric Generation - Waste Coal - Circulating 

Fluidized Bed Combustion 

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

Exhaust Duct 0 82.625 64.375 72.367 54 54 4 3

Stack 108 0 0 108 1812 1860 2 6

Target

Parameter 

Test

Method

Number of

Test Runs

Test Run

Duration

Sample 

Location Points Comments

Exhaust Duct Carbon Monoxide Method 10 3 120 0

Exhaust Duct Custom Method 18 3 120 0 Methane

Total organic compounds 

(TOC) as Propane

Exhaust Duct Method 25A 3 120 0

Exhaust Duct O2 Method 3A O2 0 During each test run

Sunday, January 30, 2011 Page 2 of 12
Mount Carmel Cogen - ICR

9/29/2010

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.

Exhaust Duct Co2 Method 3A CO2 0 During each test run

Exhaust Duct Sulfur Dioxide Method 6C 3 120 0

Flowrate Method 1 - 4 0 Throughout testing 

program

Stack

Stack % H2O Method 1 - 4 0 During each test run

Custom Method 0010 3 120 0 Semi-Volatile Organic 

HAP

Stack

Stack Formaldehyde Method 0011 3 120 0

Stack Custom Method 0031 3 120 0 Volatile Organic HAP

Sunday, January 30, 2011 Page 3 of 12
Mount Carmel Cogen - ICR

9/29/2010

Sampling / Stack Data Results Summary

Location Exhaust Duct - Method 10

Average

Run Number 1 2 3

Test Date 6/22/2010 6/22/2010 6/22/2010

Run Start Time 7:30:00 AM 10:33:00 

AM

1:44:00 PM

Run Finish Time 9:29:00 AM 12:22:00 

PM

3:43:00 PM

Carbon Dioxide, % 12.23 12.64 12.71 12.527

Oxygen, % 8.23 7.72 7.73 7.893

Dry Volumetric Flow Rate, dry scfm 194336 194463 194463 194,420.667

F-Factor, dscfm/MMBtu @ %O2 10865 11255 11255 11,125.000

Moisture, % 7.41 6.87 6.87 7.050

Fuel Type Override Override Override

Fw 0 0 0 0.000

Fc 0 0 0 0.000

Location Exhaust Duct - Method 25A

Average

Run Number

Test Date

Run Start Time

Run Finish Time

Carbon Dioxide, %

Oxygen, %

Dry Volumetric Flow Rate, dry scfm

F-Factor, dscfm/MMBtu @ %O2

Moisture, %

Fuel Type

Fw

Fc

Sunday, January 30, 2011 Page 4 of 12
Mount Carmel Cogen - ICR

9/29/2010

Location Exhaust Duct - Method 6C

Average

Run Number

Test Date

Run Start Time

Run Finish Time

Carbon Dioxide, %

Oxygen, %

Dry Volumetric Flow Rate, dry scfm

F-Factor, dscfm/MMBtu @ %O2

Moisture, %

Fuel Type

Fw

Fc

Sunday, January 30, 2011 Page 5 of 12
Mount Carmel Cogen - ICR

9/29/2010

Emissions Summary

Process Run Data

Location: Exhaust Duct - Method 10

Compound: Carbon Monoxide

Average

Run 1 2 3

lb/mmBtuO2 7.24E-02 8.06E-02 7.92E-02 0.077

ppm 5.56E+01 6.21E+01 6.10E+01 59.567

ppm@7%O2 6.10E+01 6.55E+01 6.44E+01 63.633

Location: Exhaust Duct - Method 25A

Compound: Total organic compounds (TOC) as 

Average

Run 1 2 3

lb/mmBtuO2 1.14E-03 6.11E-04 7.49E-04 0.001

ppm 5.56E-01 2.99E-01 3.66E-01 0.407

ppm@7%O2 6.10E-01 3.15E-01 3.86E-01 0.437

Location: Exhaust Duct - Method 6C

Compound: Sulfur Dioxide

Average

Run 1 2 3

lb/mmBtuO2 8.65E-02 1.30E-01 1.09E-01 0.109

ppm 2.90E+01 4.38E+01 3.68E+01 36.533

ppm@7%O2 3.18E+01 4.62E+01 3.88E+01 38.933

Sunday, January 30, 2011 Page 6 of 12
Mount Carmel Cogen - ICR

9/29/2010

Process Run Data

Run Name Value UOM Comments

Target

Value

1 Anthracite Waste (Culm) Fuel Feed 78.33 TPH Run 1 M0011, 

6/21/10 13:22-

15:29

0

1 Steam Flow 420 klbs/hr 0

1 Mega Watt output 40.09 MW 0

1 Stack Moisture 5.79 % 0

1 Stack Flow Rate 191177 scfm 0

1 Stack Temperature 318 F 0

1 Stack O2 7.86 % 0

1 Stack CO2 12.46 % 0

2 Anthracite Waste (Culm) Fuel Feed 75 TPH Run 2 M0011, 

Run 1 M25A, M10 

& M6C, 6/22/10 

7:30-9:35

0

2 Steam Flow 420 klbs/hr 0

2 Mega Watt output 40.73 MW 0

2 Stack Moisture 7.41 % 0

2 Stack Flow Rate 194336 scfm 0

2 Stack Temperature 315 F 0

2 Stack O2 8.23 % 0

2 Stack CO2 12.23 % 0

3 Anthracite Waste (Culm) Fuel Feed 78.33 TPH Run 3 M0011, 

Run 2 M25A, M10 

& M6C - 6/22/10 

10:20-12:27

0

3 Steam Flow 420 klbs/hr 0

3 Mega Watt output 40.56 MW 0

3 Stack Moisture 6.87 % 0

3 Stack Flow Rate 194463 scfm 0

3 Stack Temperature 316 F 0

3 Stack O2 7.72 % 0

3 Stack CO2 12.64 % 0

4 Anthracite Waste (Culm) Fuel Feed 78.3 TPH Run 3 M25A, M10 

& M6C - 6/22/10 

13:44-15:43

0

4 Steam Flow 420 klbs/hr 0

4 Mega Watt output 40.94 MW 0

Sunday, January 30, 2011 Page 7 of 12
Mount Carmel Cogen - ICR

9/29/2010

APCD Run Data

4 Stack Moisture 6.87 % 0

4 Stack Flow Rate 194463 scfm 0

4 Stack Temperature 316 F 0

4 Stack O2 7.73 % 0

4 Stack CO2 12.71 % 0

5 Anthracite Waste (Culm) Fuel Feed 72.7 TPH Run 1 M0010 & 

M0031 - 6/23/10 

7:17-9:25

0

5 Steam Flow 420 klbs/hr 0

5 Mega Watt output 40.27 MW 0

5 Stack Moisture 6.54 % 0

5 Stack Flow Rate 185535 scfm 0

5 Stack Temperature 318 F 0

5 Stack O2 8.08 % 0

5 Stack CO2 12.27 % 0

6 Anthracite Waste (Culm) Fuel Feed 71 TPH Run 2 M0010 & 

M0031 - 6/23/10 

10:50 - 12:58

0

6 Steam Flow 419 klbs/hr 0

6 Mega Watt output 39.91 MW 0

6 Stack Moisture 7.19 % 0

6 Stack Flow Rate 188154 scfm 0

6 Stack Temperature 312 F 0

6 Stack O2 8.06 % 0

6 Stack CO2 12.25 % 0

7 Anthracite Waste (Culm) Fuel Feed 66.8 TPH Run 3 M0010 & 

M0031 - 6/24/10 

7:55-10:25

0

7 Steam Flow 418 klbs/hr 0

7 Mega Watt output 39.69 MW 0

7 Stack Moisture 7.07 % 0

7 Stack Flow Rate 189265 scfm 0

7 Stack Temperature 309 F 0

7 Stack O2 8.23 % 0

7 Stack CO2 12.05 % 0

Run Name Value UOM Comments

Target

Value

1 BAGHOUSE 12 " H2O 0

Sunday, January 30, 2011 Page 8 of 12
Mount Carmel Cogen - ICR

9/29/2010

Process Lab Run Data

1 12 " H2O 0

2 BAGHOUSE 12 " H2O 0

3 BAGHOUSE 12 " H2O 0

4 BAGHOUSE 12 " H2O 0

5 BAGHOUSE 12 " H2O 0

6 BAGHOUSE 12 " H2O 0

7 BAGHOUSE 12 " H2O 0

1 DRY LIMESTONE INJECTION 6.78 TPH 0

2 DRY LIMESTONE INJECTION 6.22 TPH 0

3 DRY LIMESTONE INJECTION 6.44 TPH 0

4 DRY LIMESTONE INJECTION 7.69 TPH 0

5 DRY LIMESTONE INJECTION 7.13 TPH 0

6 DRY LIMESTONE INJECTION 6.48 TPH 0

7 DRY LIMESTONE INJECTION 7.25 TPH 0

Sunday, January 30, 2011 Page 9 of 12
Mount Carmel Cogen - ICR

9/29/2010

Sampling / Stack Data Results Detail

Location Exhaust Duct - Method 10

Average

Run Number 1 2 3

Test Date 6/22/2010 6/22/2010 6/22/2010

Run Start Time 7:30:00 AM 10:33:00 AM 1:44:00 PM

Run Finish Time 9:29:00 AM 12:22:00 PM 3:43:00 PM

Carbon Dioxide, % 12.23 12.64 12.71 12.527

Oxygen, % 8.23 7.72 7.73 7.893

Fuel Factor 1.04 1.04 1.04

Dry Volumetric Flow Rate, dry scfm 194336 194463 194463 194,420.667

F-Factor, dscfm/MMBtu @ %O2 10865 11255 11255 11,125.000

Moisture, % 7.41 6.87 6.87 7.050

Analyzer Make Thermo 

Electron

Thermo 

Electron

Thermo 

Electron

Analyzer Model 48C 48C 48C

Analyzer Serial Number 48C-54732-

301

48C-54732-

301

48C-54732-

301

Operating Range 126 126 126 126.000

Operating Units ppm ppm ppm

No. Readings/Avg. 120 120 120 120.000

Calibration Set 4 5 6 5.000

Calibration Pre Zero Cylinder ID CC133012 CC133012 CC133012

Calibration Pre Zero Cylinder Instrument Response 0.41 0.69 0.15 0.417

Calibration Pre Zero Cylinder Bias 0.19 0.41 -0.02 0.193

Calibration Pre Zero Cylinder Drift 0 0 0 0.000

Calibration Pre High Cylinder ID CC-91200 CC-91200 CC-91200

Calibration Pre High Cylinder Instrument Response 49.78 50.8 48.99 49.857

Calibration Pre High Cylinder Bias 1.97 2.78 1.34 2.030

Calibration Pre High Cylinder Drift 0 0 0 0.000

Calibration Post Zero Cylinder ID CC133012 CC133012 CC133012

Calibration Post Zero Cylinder Instrument Response 0.69 0.15 -0.5 0.113

Calibration Post Zero Cylinder Bias 0.41 -0.02 -0.53 -0.047

Calibration Post Zero Cylinder Drift 0.22 0.43 0.51 0.387

Calibration Post High Cylinder ID CC-91200 CC-91200 CC-91200

Calibration Post High Cylinder Instrument Response 50.8 48.99 48.73 49.507

Calibration Post High Cylinder Bias 2.78 1.34 1.13 1.750

Calibration Post High Cylinder Drift 0.81 1.44 0.21 0.820

Cavg 56.19 62.24 60.03 59.487

Cavg Units ppmvd ppmvd ppmvd

Cgas 55.5953 62.1011 61.0215 59.573

Cgas Units ppmvd ppmvd ppmvd

Fuel Type Override Override Override

Fw 0 0 0 0.000

Fc 0 0 0 0.000

Cgasw 0 0 0 0.000

Cgasw Units

Sunday, January 30, 2011 Page 10 of 12
Mount Carmel Cogen - ICR

9/29/2010

Location Exhaust Duct - Method 25A

Average

Run Number

Test Date

Run Start Time

Run Finish Time

Carbon Dioxide, %

Oxygen, %

Fuel Factor

Dry Volumetric Flow Rate, dry scfm

F-Factor, dscfm/MMBtu @ %O2

Moisture, %

Analyzer Make

Analyzer Model

Analyzer Serial Number

Operating Range

Operating Units

No. Readings/Avg.

Calibration Set

Calibration Pre Zero Cylinder ID

Calibration Pre Zero Cylinder Instrument Response

Calibration Pre Zero Cylinder Bias

Calibration Pre Zero Cylinder Drift

Calibration Pre High Cylinder ID

Calibration Pre High Cylinder Instrument Response

Calibration Pre High Cylinder Bias

Calibration Pre High Cylinder Drift

Calibration Post Zero Cylinder ID

Calibration Post Zero Cylinder Instrument Response

Calibration Post Zero Cylinder Bias

Calibration Post Zero Cylinder Drift

Calibration Post High Cylinder ID

Calibration Post High Cylinder Instrument Response

Calibration Post High Cylinder Bias

Calibration Post High Cylinder Drift

Cavg

Cavg Units

Cgas

Cgas Units

Fuel Type

Fw

Fc

Cgasw

Cgasw Units

Sunday, January 30, 2011 Page 11 of 12
Mount Carmel Cogen - ICR

9/29/2010

Location Exhaust Duct - Method 6C

Average

Run Number

Test Date

Run Start Time

Run Finish Time

Carbon Dioxide, %

Oxygen, %

Fuel Factor

Dry Volumetric Flow Rate, dry scfm

F-Factor, dscfm/MMBtu @ %O2

Moisture, %

Analyzer Make

Analyzer Model

Analyzer Serial Number

Operating Range

Operating Units

No. Readings/Avg.

Calibration Set

Calibration Pre Zero Cylinder ID

Calibration Pre Zero Cylinder Instrument Response

Calibration Pre Zero Cylinder Bias

Calibration Pre Zero Cylinder Drift

Calibration Pre High Cylinder ID

Calibration Pre High Cylinder Instrument Response

Calibration Pre High Cylinder Bias

Calibration Pre High Cylinder Drift

Calibration Post Zero Cylinder ID

Calibration Post Zero Cylinder Instrument Response

Calibration Post Zero Cylinder Bias

Calibration Post Zero Cylinder Drift

Calibration Post High Cylinder ID

Calibration Post High Cylinder Instrument Response

Calibration Post High Cylinder Bias

Calibration Post High Cylinder Drift

Cavg

Cavg Units

Cgas

Cgas Units

Fuel Type

Fw

Fc

Cgasw

Cgasw Units

Sunday, January 30, 2011 Page 12 of 12