## Prepared for: 

# HANSON BRICK Pleasant Garden, North Carolina

Hanson Brick P.O. Box 368 Pleasant Garden, North Carolina 27313
/ Site: Hanson Brick P.O. Box 549 2014 Morris Creek Road Stanton, Kentucky 40380

30-05016.00 December 30, 2004 

## Clayton Group Services,Inc. 39830 Grand River Avenue, Suite B-2 Novi, Michigan 48375-2134

248:344.2661

### ~ 

# Claytori CONTENTS Section Page 1.0 INTRODUCTION ................................................................................................. 1 2.0 SUMMARY OF RESULTS ................................................................................. 1 2.1 BAGHOUSE PM AND VISUAL EMISSIONS ..................................................... 1 2.2 OLD AND NEW KILN PM AND HF EMISSIONS .............................................. 2 3.0 SITE DESCRIPTION ........................................................................................... 2 4.0 SAMPLING AND ANALYTICAL PROCEDURES ......................................... 3 4.1 EXHAUST GAS COMPOSITION AND FLOWRATE ........................................ 3 4.2 PARTICULATE EMISSIONS .......................:....................................................... 3 4.3 HYDROGEN FLUORIDE EMISSIONS ................................................................ 4 4.4 VISUAL EMISSIONS ............................................................................................ 4 Limitations...................................................................................................:.................. 5 Tables 1 Particulate Summary Table 1 2 Particulate and Hydrogen Fluoride Summary Table 2 ' 3 Particulate and Hydrogen Fluoride Summary Table 3

Figures 1 Sampling Port and Traverse Point Locations

, 2 Old and New Lingl Kiln Exhaust Stacks

3 USEPA Method 17 Sampling Train 4 USEPA Method 5/26A Sampling Train Appendices A USEPA METHOD 5/17 AND 26 FIELD AND COMPUTER-CALCULATED 

# DATASHEETS B USEPA METHOD 5/17 AND 26 LABORATORY RESULTS C USEPA METHOD 5/17 AND 26 CALIBRATION DATA SHEETS D USEPA METHOD 9 FIELD DATA SHEETS E GRINDING AND PRODUCTION RATES DURING TEST PERIODS F OBSERVER'S USEPA METHOD 9 CERTIFICATION LETTER

ii

# 1 Claytori

1.0 INTRODUCTION Hanson Brick (Hanson) retained Clayton Group Services (Clayton) to conduct particulate matter (PM), visible emissions (VE) and hydrogen fluoride (HF) testing of NSPS affected sources at their facility in Stanton, Kentucky. The purpose of this testing was to provide Hanson with PM, VE, and HF data to be submitted to the Kentucky Department for Environmental Protection, Division of Air Quality (KDEP-DAQ) to determine compliance with conditions of Air Permit No. V-03- 013. Messrs. Mark D. Westerberg, Project Manager, and Fred W. Meinecke, Environmental Technician with Clayton, performed the testing on consecutive days, November 30 and December 1 and 2, 2004. Mr. Dale Overcash, P.E., Director, Air Quality Services with Clayton's Raleigh Regional Office, provided technical assistance for this study. Mr. Jack Garvey, Director of Engineering, with Hanson, provided technical assistance for this study. Mr. Jeff Brewer, Plant Manager, with Hanson's Stanton facility provided process operation assistance forthis study. Messrs. John Jayne, and Jeremy Ray, Environmental Engineers, with KDEPDAQ, observed the testing. 2.0 SUMMARY OF RESULTS The testing conducted at the Stanton facility was performed utilizing United States Environmental Protection Agency (USEPA) Methods 5, 9, 17, and 26A. 2.1 BAGHOUSE PM AND VISUAL EMISSIONS Hanson has identified conveyor C-11, a double-deck scalping screen (SS-1), and two screens (MS-1 and MS-2) as NSPS-affected sources that are controlled by the baghouse (Emission Point No. 001) at the Stanton facility. One (1) 40 CFR 60, Subpart 000, Standards of Performance for Nonmetallic Mineral Processing Plants, NSPS affected source (EP No. 001) was tested for PM emissions and observed for VE's. The average test results and associated limits are listed in the following table:

Source PM OPacity ID Type Limit (lb/hr) 3-Test Ave.

(lb/hr) Limit



## °/a) Highest 6-

min. Ave. EP No. 001 

# 1 baghouse 8.0 0.0486 10% 

# 1 0% The PM field and computer-calculated data sheets for the USEPA Method 17 testing conducted at the Stanton facility are presented in Appendix A. The USEPA Method 17

# /1 

# Claytori

laboratory results are presented in Appendix B. Calibration data sheets associated with the USEPA Method 17 testing can be viewed in Appendix C. The VE data sheets from the USEPA Method 9 testing of the baghouse (EP No. 001) exhaust stack conducted at the Stanton facility are presented in Appendix D. The Grinding Rate on November 30, 2004 for the Grinding & Screening operation was 42.6 tons/hr. The calculations for the Grinding Rate as provided by Hanson are presented in Appendix E. The observer's USEPA Method 9 certification sheet is included in Appendix F. 2.2 OLD AND NEW KILN PM AND HF EMISSIONS Hanson has identified the Old Lingl Kiln (EP No. 002) and New Lingl Kiln (EP No. 003) as emission sources subject to particulate and hydrogen fluoride emission testing at the Stanton facility. The two kilns were tested for PM and HF emissions. The results of the testing are listed in the following table:

Source Particulate Matter Hydrogen Fluoride ID Type Limit Test Result Limit Test Result EP No. 002 Old Lingl

Kiln 13.03 lbs/hr 2.841bs/hr *n/a 5.99 lbs/hr EP No. 003 New Lingl

Kiln 13.86 lbs/hr 2.951bs/hr *n/a 6.341bs/hr ' 

### *not applicable- there is no set kiln enussion limit for hydrogen fluoride in the permit. 

## The Production Rates on December 1 and 2, 2004 for the Old and New Lingl Kilns operations were 7.56 and 8.06 tons/hr, respectively. This meets the throughput limits of 8.0 and 8.84 tons/hr for the Old and New Lingl Kilns, respectively, set for in the pennit. The calculations for the Production Rate as provided by Hanson are presented in Appendix E. 3.0 PROCESS DESCRIPTION Hanson Brick manufactures bricks at its facility in Stanton, Kentucky. The Grinding & Screening operations process raw materials for the manufacture of bricks. The Grinding & Screening operations consist of primary crushers, screens, and conveyors, which deliver the raw materials to the brick making operation. The green bricks are then loaded onto cars and conveyed to either one of two kilns for curing. The cars are pushed through the kilns at a rate of approximately 15 cars per day.

2

# AClaytori

4.0 SAMPLING AND ANALYTICAL PROCEDURES 4.1 EXI3AUST GAS COMPOSITION AND ELOWRATE USEPA Methods 1 and 2, from the Code of Federal Regulations, Title 40, Part 60, Appendix A(40 CFR 60, Appendix A), were used to determine the number of traverse points and to perform velocity profile measurements. An S-type pitot tube and thermocouple assembly, calibrated in accordance with USEPA Method 2, Section 10.0, was used to measure exhaust gas velocity pressures and temperatures during testing. Because the dimensions outlined in Sections 10.1.1 through 10.1.5 were within the specified limits, the baseline pitot® tube coefficient of 0.84 (dimensionless) was assigned. Molecular weight determinations were evaluated according to USEPA Method 3, "Gas Analysis for the Determination of Dry Molecular Weight." The equipment used for this evaluation consisted of (1) a stainless-steel probe of suffrcient length to reach the centroid of the duct, (2) a one-way squeeze bulb with connecting tubing and (3) a set of Fyrite® combustion gas analyzers. Carbon dioxide and oxygen content were analyzed using the Fyrita procedure at the baghouse exhaust and each kihi oven exhaust.During the preliminary traverse, moisture content was approximated using the wetbulb/dry-bulb method described in USEPA Method 4, "Determination of Moisture Content in Stack Gases." This data was used in conjunction with the velocity and temperature data to determine the isokinetic-sampling rate. For each particulate sampling event, actual moisture content of the exhaust gases was measured using the reference method outlined in Section 2 of USEPA Method 4. 4.2 PARTICULATE EMISSIONS USEPA Methods 5(kiln testing) and 17 (baghouse testing) were used to evaluate particulate concentrations and emission rates (see Figure 1 for a schematic of the baghouse exhaust and Figure 2 for a schematic of the both kiln exhaust sampling locations). One pre-weighed Whatman 47mm or 110mm glass fiber filter was used to collect the filterable PM for each test. No deviations from the reference test methods were used during the testing. See Figures 3 and 4 for schematics of the USEPA Method 17 and 5 sampling trains, respectively. Initially, each filter was desiccated for a minimum of 24 hours, weighed, desiccated another 6 hours (minimum), and re-weighed. If weights agreed within 0.5 milligrams (mg), the filter was placed in an airtight, labeled container until use. . Nozzle, probe (Method 5 only), and filter holder assemblies were brushed and rinsed with acetone three times. The acetone rinses were collected in a labeled pre-cleaned sample container. The outside of the container was labeled with the test number, test location, and test date. The level of liquid was marked on the outside of the container. Immediately after recovery, the sample containers were placed in a sealed cooler for

# !1 Claytori

storage. All sample containers were hand carried by Clayton personnel to Clayton's laboratory in Novi, Michigan. Filters and nozzle rinses were analyzed gravimetrically at Clayton's laboratory in Novi, Micbigan. Each drying beaker was initially desiccated for approximately 24 hours, until a constantweight was obtained. The acetone samples were then quantitatively transferred to preweighed drying beakers. The acetone was driven off and the beakers with the particulate from the acetone rinse were desiccated for an additional6 hours, and then re-weighed. If weights did not remain constant (within 0.5 mg), the beakers were further desiccated for 6-hour increments until a constant weight was attained. The Whatman 47mm and 110mm glass frber filters were similarly treated until a constant weight was obtained. 4.3 HYDROGEN FLUORIDE Hydrofluoric acid concentrations were determined via triplicate 60-minute test runs at the old (EP No. 002) and new (EP No. 003) kiln oven exhausts. The USEPA Method 26A sampling train was combined with the USEPA Method 5 sampling train for the kiln emissions testing. The sampling train was assembled in the following sequence: (1) glass sampling nozzle, (2) 5-foot-long effective glass samplingprobe, (3) heated filter box assembly with a glass filter holder containing a tared 110 mmdiameter washed quartz filter, (4) two standard impingers, each containing 100 ml of 0.1N H2SO4 solution, (5) two modified impingers containing 100 ml of 0.1N NaOH, and (6) one modified impinger containing approximately 300 grams of silica gel. See Figure 4 for a schematic of the modified USEPA Method 5 sampling train used. In addition to the collection of HF in the impingers, Clayton measured the amount of liquid collected during each sampling ran and utilized this data to determine the moisture content of the gas stream. Laboratory analysis for HF was performed by Clayton's laboratory in Novi, Michigan 4.4 VISUAL EMISSIONS VE observations were conducted in accordance with the procedures outlined in USEPA, "Standards of Performance for New Stationary Sources" (Federal Register, 40 CFR 60), Method 9, "Visual Determination of the Opacity of Emissions from Stationary Sources." The grinding & screening operations were maintained at their normal high loads. The grinding rates were monitored and calculated during the test periods. The observer's USEPA Method 9 certification sheet is included in Appendix E

# '1 Claytorri

Limitations The information and opinions rendered in this report are exclusively for use by Hanson Brick. Clayton Group Services will not distribute or publish this report without Hanson Bricks' consent except as required by law or court order. The information and opinions are given in response to a limited assignment and should be implemented only in light of that assignment. Clayton Group Services accepts responsibility for the competent performance of its duties in executing the assignment and preparing reports in accordance with the normal standards of the profession, but disclaims any responsibility for consequential damages. This report prepared by: (`~~ (~, ~ 

## / Mark D. Westerberg Y 

## Consultant, Air Quality Management Environmental Services Detroit Regional Office
This report approved by: Dale Overcash, P.E. Vice-President 

## Raleigh Regional Office December 30, 2004. ........ -tiL LATE 

### SUMM : 

## -AIRY T 

## . AR

................... ... .. ..... .....

...........

.......... ....... ... 

### Z _ 11 , 1 QIZ 

### A ge Meter Temperature Tm (F) 

### 65.1 71.5 72.4 

### 693 Meter Pressure 

### - Pm (in. 

### Hg) 30.3 30.3 30.3 30.3 Measured Sample Volume (Vm) 

### 99.5 98.5 101.0 99.7 Sample Volume (Vm-Std 

### ft3) 102 

### 100 102 

### 101 Sarnple Volume (Vm-Std m3) 

### 2.88 2.82 

### 2.89 2.86 Condensate Volume (Vw-std) 0.94 

### 1.13 1.08 

### 1.05 Gas Density (Ps(std) lbs/ft3) 0.0743 0.0742 0.0742 0.0742 Total weight of sainpled gas (m 

### g lbs) 7.64 

### 7.47 7.65 7.59 Nozzle Size 

### - An (sq. ft.) 

### 0.000177 0.000171 0.000177 0.000175 Isokinetic Variation 

### - 1 98.7 98.8 98.7 98.7 

### Stack Data. Average Stack Temperature 

### - Ts (F) 

### 59.0 58.6 59.0 58.9 Molecular Weight Stack Gas- dry 

### (Md) 28.8 28.8 28.8 28.9 Molecular Weight Stack Gas-wet (Ms) 

### 28.7 28.7 28.7 28.7 Stack Gas Specific Gravity (Gs) 

### 0.992 0.992 0.992 0.992 Percent Moisture (Bws) 

### 0.916 1.12 

### 1.05 1.03 Water Vapor Volume (fraction) 

### 0.00916 0.0112 

### 0.0105 0.0103 Pressure 

### - Ps 

### ("Hg) 29.3 29.3 29.3 29.3 Average Stack Velocity -Vs (ft/sec) 

### 81.8 82.6 82.0 82.1 Area of Stack (ft2) 3.14 3.14 3.14 3.14 

### tiSf W,7 Flowrate ffl(Actual) 15,413 

### 15,577 15,457 15,482 Flowrate 

### ft3 (Standud Wet) 

### 15,392 15,568 15,436 15,466 Flowrate 

### $3 (Standard Dry) 

### 15,251 15,394 15,274 

### 15,306 Flowrate m3 (standard dry) 432 436 433 433
Filter/Nozzle-Filter holder assembly wash 1.200 4.80 1.200 2.40 Blank correction 

### 0.00 0.00 0.00 0.00 Total 1.200 4.80 1.200 2.40 

## Tiata ir 

# Pa rt i eu 

### l a 

### t e 

### C f 

### sn ce 

## n trat

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## a . 

## n: ; , 1b/1000 lb (dry) 0.000348 0.001426 0.000348 

### 0.000707 

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### ffeu r j 4 Eii3 i 

### ss r



### an j
1b/ hr 

### 0.023765 0.098147 0.023765 0.0486

### Mbto.Joog,crmvzn7o,(F) 59.9 707 76.4 69.0

k8merPrnourn'Pm(iu.E|Q) 304 304 30.4 30.4 Mousn/rd0umy[e\/olnm:(`/ou) 574 582 56.8 57.5 Juopl:Vo\umo(`/uo'Std ft3) 59.6 59.3 572 58.7 3umplevoiucuo(`/ou'0/dnu3) L69 1.68 1.62 1.66 Coudouootn\/o[uzue(Y«'o*d) 2.54 3.15 3.30 3.00 0uxDoudty(Po(md)lhs/ft3) 0.0742 0.0739 0.0738 0.0740 T/uulwni&btofoucup(nd guy(zuglhs) 4.61 4.62 446 4.56 0nxz|o8izc-Au(og. ft) 0.000346 0.800346 0.000346 0.000346 IsokiurticYubmiou'I 98.6 98.5 1004 992

### Tat

Motor7ompermooTm(y) 62.5 74J 81.8 73.0 MntoProvsmn'Pou(iu.Bg) 304 30.4 304 304 MeuonrodSuogpinVobzoe(\/on) 53.5 519 55.6 53.7 SoopinVolomn(Ym'Stdd3) 55.3 524 55.4 54.3 SmupbVoluouo(Yu+8tdm3) 1.56 148 lJ? 154 Coodouootc\/o}uzun(\/`n'otd) 7.13 2.82 2.38 2.78 8usDoo^ity(Ps(xtd)lhs/ft3) 0.0736 0.0737 0.0740 0.0737 Tvtu}weigLuofsumylnd&uo(ou&}hd 430 4.07 427 421 lyozzlnSizo'Au(xg. ftj 0.000601 0.000681 0.000627 0.000610 I^vkiuobo\/uriauiou'I 101 99.9 99.5 100

# A Claytori

FIGURES

# 035" 048"

Old Kiln Exhaust = 035" New Kiln Exhaust = 048"

Distance from Distance from Sampling Point Stack Wall Sampling Point Stack Wall

(inches) (inches) 6 1.54 6 2.11 5 5.11 5 7.01 4 10.36 4 14.21 3 24.64 3 33.89 2 29.89 2 40.94 1 33.43 1 45.84

Figure 2 Old & New Lingl Kiln E ~ taust y~



# ~~~~ ®11 ~ Hanson Brick i I H anson Brick

Stanton, Kentucky

. Stacks N Stanton; Kentucky e GROUP SERVICES PmjeaNO.30.0301E.00 T

### In-Stack 

### Temperature Filter Holder Sensor 

# ~ / II

/•'!/ / Probe 

### * Suggested (Interference-Free) Spacings

Type-S 

# ~ Pitot Tube and Thennocouple

Probe 

### Sampting Temperature Sensor Extensit Nozzle /

In-Stack 

### Filter Stack Holder Wall Reverse-Type 

### Pitot Tube Pitot Manometer Impinger Train optional, inay be replaced by an equivalent condenser
Flexible Thermometer %bing Check Valve 

## r ------- ------- 7 

### a '

.. .. . ..

s. Line



### Orifice Manometer Dry Gas Meter Ice Bath Valve , Main Valve

~ 

# ~ Air-Tight J 

### Pump 

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Figure 3 , i i Hanson Brick USEPA Method 17 Sam lin 

# ~ ~ 

# laytori Hanson Brick T P g Stanton, Kentucky Train N Stanton, Kentucky E _ G R O U P 5 E R V I C E 5 T PmjeeNO.30ni0t600 i

~ ERa'iaon pttanEC18,I00.t

### ~ 

# Claytori

APPENDIX A USEPA METHOD 5/17 Ai °VD 26A FIELD COVIPUTER-CALCULATED DATA 

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### USEPA A'LETHOD 2 GAS VELOCITY TRAVERSE AND VOLUMETRIC FLOWRATE DATA SHEET

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TRAVERSE POINT YUMBER VELOCITY

HEAD (LP) in.H2O STACK

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APPENDdX B USEPA iVIETHOD 5/17 AND 26A LABORATORY RESULTS~ 

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# Claytori

G R O U P S E R V I C E S 22345 Roethel Drive Novi, MI 48375 248.344.1770 Fax 248.344.2654 

## December 10, 2004 

## Mark Westerberg CLAYTON ES DETROIT 39830 Grand River Suite B-2 Novi, MI 48375- Clayton Work Order No. 04120183 Reference: 30-05016.00/IENSON BRICK 

## Dear Mark Westerberg: Clayton Group Services received 7 samples on 12/3/2004 for the analyses presented in the following report. Enclosed is a copy of the Chain-of-Custody record, acknowledging receipt of these samples. Please note that any unused portion of the samples will be discarded 30 days after the date of this report, unless you have requested otherwise. This material is confidential and is intended solely for the person to whom it is addressed. If this is received in error, please contact the number provided below. We appreciate the opportunity to assist you. If you have any 

## questions concerning this report, please contact a Client Services Representative at (800) 806-5887. 

## Sincerely, ?

Sharon Johnson Client Services Representative cc:

www.claytongrp.com

Environmental Services • Occupational Health and Safety - Laboratory Services

# ~ Claytori

CASE 

# N ARRATIVE Date: 10-Dec-04 

### CLIENT: CLAYTON ES DETROIT Project: 30-05016.00/HENSON BRICK work Order No 04120183 

## Analytical comments: The Clayton Novi Laboratory is NELAP and AIHA accredited. These acereditations require that we provide the following information on each report: As an analytical result progresses above the reporting limit (RL), it has less variability than a result reported at, or near, the RL. Samples were received at the laboratory at an average temperature of °C.

118

# %% ZClaytori ANALY 

# TICAL RESULTS Date: 10-Dec-04 CLIENT: CLAYTON ES DETROIT Client Sample ID: OLD KILN EX-11-1 Work Order No: 04120183 Tag Number: Project: 30-05016.00/HENSON BRICK Collection Date: 12/I/2004 Lab ID: 04120183-OOlA Matrix: AIR Reporting Analyses Result Limit Qual Units DF Date Analyzed Analyst EPA 26 Hydrofluoric Acid 

### 140,000 350 ug 325 12/8/2004 MJK

Qualifiers: ND - Not Detected at the Reporting Limit (RL). S- Spike Recovery outside accepted recovery limits

J- Malyte detected below the Reporting Limlt R- RPD outside accepted recovery limits B- Malyte detected in the associated Method Blank E- Value above quantitatiom mnge '- Value exceeds Maximum Contaminant Level T - Tentztively Identified Compound (TIC)
218

# ~ Claytori 

# ANALYTICAL RESULTS Date: 10-z>ec-04 

### CLIENT: CLAYTON ES DETROIT Client Sample ID: OLD ffiLN EX-P-2 Work Order No: 04120183 Tag Number: Project: 30-05016.00/FENSON BRICK Collection Date: 12/1/2004 Lab ID: 04120183-002A Matrix: AIR Reporting 

### Analyses Result Lim9t Qual Units DF Date Analyzed Analyst EPA 26 Hydrofluoric Acid 140,000 350 99 325 12/8/2004 MJK

Qualifiers: ND -Not Detected at the Reporting Limit (RL). S- Spike Recovery outside accepted recovery limits

J- Analyte detected below the Reporting Limit R- RPD outside accepted recovery limits B- Analyte detected in the associated Method Blank E- Value above quantitation range '- Value exceeds Maximum Contaminant Level T - Tentatively IdentiBed Compound (TIC) 

### 318

# ~ Claytori ANALYTICAL RESULTS Date: ro-Dec-oa CLIENT: CLAYTON ES DETROIT Client Sample ID: OLD KILN EX-P-3 Work Order No: 04120183 Tag Number: Project: 30-05016.00/I-IENSON BRICK Collection Date: 12/1/2004 Lab ID: 04120183-003A Matrix: AIR Reporting Analyses Result Limit Qual Units DF Date Analyzed Analyst EPA 26 Hydrofluoric Acid 140,000 350 99 325 12/8/2004 MJK

Qualiflers: ND -Not Detected at the Reporting Limit (RL). S- Spike Recovery outside accepted recovery limits

J- Malyte detected below the Reporting Limit R- RPD outside accepted recovery limits B- Malyte detected in the associated Method Blank E- V alue above quantitation range '- Value exceeds Maximum Contaminant Level T - Tentatively Identified Compound (TIC) 4/8

# ~ Clayt®ri ANALYTICAL RESULTS Date: 10-Dec-04 

### CLIENT: CLAYTON ES DETROIT Client Sample ID: NEW KILN EX-P-1 Work Order No: 04120183 Tag Number: Project: 30-05016.00/HENSON BRICK Collection Date: 12/1/2004 Lab ID: 04120183-004A Matrix: AIR 

### Reporting Analyses Result Limit Qual Units DF Date Analyzed Analyst EPA 26 Hydrofluoric Acid 140,000 350 μg 325 12/8/2004 MTK

Qualifiers: ND -Not Detected at the Reporting Limit (RL). S- Spike Recovery outside accepted recovery limits

J- Malyte detected below the Reporting Limit R- RPD outside accepted recovery limits B - Analyte detected in the assocfated Method Blank E- Value above quantitatiom mnge *- Value exceeds Maximum Contaminant Level T -Tentatively Identified Compound (TIC) 

### 518

# / '1Claytori 

# ANALYTICAL RESULTS Date: 10-Dec-04 CLIENT: CLAYTON ES DETROIT Client Sample ID: NEW KILN EX-P-2 Work Order No: 04120183 Tag Number: Project: 30-05016.00/fENSON BRICK Collection Date: 12/1/2004 Lab ID: 04120183-005A Matrix: AIR Reporting Analyses Result Limit Qua] Units DF Date Analyzed Analyst EPA 26 HydrofluoricAcid 

### 130,000 350 μg . 325 12/8/2004 MJK

Qualifiers: ND -Not Detected at the Reporting Limit (RL). S- Spike Recovery outside accepted recovery limits

J- Analyte detected below the Reporting Limit R- RPD outside accepted recovery limits B- Malyte detected in the associated Method Blank E- V alue above quantitation range *- Value exceeds Maxfmum Contaminant Level T - Tentatively Identified Compound (TIC)
618

# ,A Claytori 

# ANALYTICAL RESULTS Date: 10-Dec-04 

### CLIENT: CLAYTON ES DETROIT 

### Client Sample ID: NEW KILN EX-P-3 

### Work Order No: 04120183 Tag Number: Project: 30-05016.00/HENSON BRICK Collection Date: 12/1/2004 Lab ID: 04120183-006A Matrix: AIR Reporting Analyses Result Limit Qual Units DF Date Analyzed Analyst EPA 26 Hydrofluoric Acid 250,000 350 99 325 12/8/2004 MJK

Qualifiers: ND - Not Detected at the Reporting Limit (RL). S- Spike Recovery outside accepted recovery limits

J- Malyte detected below the Reporting Limit R- RPD outside accepted recovery limits B- Analyte detected in the associated Method Blank E- Value above quantitation isnge '- Value exceeds Maximum Contaminant Level T - Tentatively Identified Compound (TIC) 7l8

# ~ Qo Claytoxri

~ o 1rE, 

# ANALYTICAL RESULTS Date: 10-Dec-09 

### CLIENT: CLAYTON ES DETROIT Client Sample ID: 0.1 H2SO4 BLANK Work Order No: 04120183 Tag Number: Project: 30-05016.00/1ENSON BRICK Collection Date: 12/1/2004 Lab ID: 04120183-007A Matrix: AIR Reporting Analyses Result Limit Qual Units DF Date Analyzed Analyst EPA 26 HydrofluoricAcid 240 110 μg 107 12/8/2004 MJK

QualiHers: ND -Not Detected at the Reporting Limft (RL). S- Spike Recovery outs{de accepted recovery limits

J- Analyte detected betow the Reporting Limit R- RPD outside accepted recovery limits B- Analyte detected in the associated Method Blank E- Value above quantitatfom mnge *- Value exceeds Maximum Contaminant Level T - Tentatively Identified Compound (1TC)
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## a G 0.32 cm (1/8 in) 

# z z~ Y~ 

# vC'' w G 0.08 cm (1/32 in) w6YS NO'



## Pitot on Probe 

## Comoonent Spacing OK 

# Pitot Tube Correction Factor 1 1 • . ...... ~ 

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## C. Y? 7. 5 2 cm ~ ~71~ I f.• w 

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or A. YES VO B-+ YES VO

8-L YE5 N0 (: YE° `0

## CRITEz`tIA CFiECXLLST

PITOT TUBE NUI7BER 1 

## T+ DATE ✓ ~ 

## w Pitot Tube not on Probe OQerator

. ~ 

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## . 3/16 L Dt - 3/8 • 0 q Pp YES Yr .48cm .95cm

~ 

## . , 

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# ~ 1.5 Dt

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## B w YE5 y0 

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# .._ Pitot on Probe Pitot Tube Correction Factor Comoonent Spacing OK . ......... ..r•....._ .«....._.,..

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## PITOT TUHE NUMBER 

# DATE Pitot Tube not on Probe 

# 3/16 :c- Dt L 3/8 .48cm .95cm PA = Pg 1.05 Dt fi P, ~ 

## 1.5 Dt
d 1 and ct2 < 10 0

# t and ,82 < 5°

a ~ 

## 0.32 cm (1/8 in) w G 0.08 cm (1/32 in)



## Pitot on Probe Comoonent Spacing OK CRITfirZIA CIiECI{LLST

V"v - )'U , -/


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# Claytori

APPENDIX D USEPA METHOD 9 EIELD DATA SHEETS

### 9ection 3.12.1 D ,/ ~ ~ 

### 6

_ April 1963 -
Visible Emrssion Otrservarion Form SOURCE NAME 

## t-ZArzSO. ~(l~ C OBSERVAT/ON DATE 

## 1f-

~~ 

### ''oLf START T1Mf



## ',7G0 STOP TIME 

### ADDRESS ,7 l~

/ G} L" 

# O 

# G

U X. 

### ~ 

### y 1 SEC M7N 0 15 30 4$ Sf M! 0 15 30 45 ' ~ 7 l/ ~ ~ 31 

# 0 C1TY

~ , .~ 114N7J{v STATE

~ l/ Z7P p y'Opg ~ 3 2 

### ~ i O 

### ~ 32 ` 

### ~ ~ 3 

# O ~ 

# D 33 I G Q G PHONE f 4 p

~ J ~ b Y'7 b s - 

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I t Z/ 

### SOURCE/D NUMBER 4 0 ~ a .74 I PROCESS EQU1PMfNT - (~ '.-<.--.J._ f ScrvC.r..-. OPERAT7NG MODE 5 ® 

## O O G 35 CONTROL fQU1PMENT ~

9~ 

## hov OPERATING MODE ' 6 D Q ~ ~ 3 6 Q o O ® Z 

### G ~ 

# 0
~ 3T 

### i 0 

# 0 ~ 1 (J ~ DESCR7BE E 7SSION POINT STAR7 ~ .. 'r~~ 

### 'fi L
~ 

### c>Z STOP ~~~ 8 Q D 38 I® 6 " ~ ' 1D HElGHT ABOVE GROUND LEVEL STAR7 ~ 'L/Q' 

### STOP ~ .Rr ~ C. HEIGHT RELATIVE TOOBSERVER START ' 1 ' Z r STOP i•'-"' v '- 9 10 O

~ O

~ ( O d D. y ~ V 39 40 I ~ 0 © C, Cl D/STANCE FROM OBSERVER START w SO l

STOP`yAy.nt_ D/RECTIONFROM 085ERVER

START S STOP ~ jvp'i._ 71 O (7 ~ Q 41 DESCR/BE EMISSIONS START nNO p/E STOP S ~VN~~ i2 O O I (' 42 

### © D 0 13 I o ~ ~ (~ 43 

### d b (] I D fMlSS/ON COLOR START N!,',a STOP PLUME 7YPE C41NT7NUOUS 

### 17 FUG7T/VEC 7NtERM7TTEN7 ❑ 14 ~ 

### G (7 ( ~ 44 

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### v WATER DROPLETS PRESENT NO

~ T YESO 

### 1F WATER DROPLETPLUME. ATTACHED O DETACHED ❑ 

### 75 ~ 

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### 45 16 G Q I Q I 

### O 46 Q ® ® Q POlNT /N THE PLUMf AT WH7Ch' OPAC7TY WAS DETERMINfD START c`^'Ld"^. 

### :"I"".
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# 7 8 G 

# a 0 0 , 48 [ ~ ~~ 

### 79 I 

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# 21 Q 1 , 0 O O 5t 

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### D
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a0° -- Sun Loca+ron Lrne 24 Q Q .0 o 54 C) 25 Q Q Q 

### C7 55 26 

## © 0 D b 56 

## I V o l7 

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### D o ~~ !
. ✓ `~ AVERAGE OPAC/TY FOR HIGHEST PERIOD 0 NUMBER OF READlNGS ABOVf C~ % WERE RANGf OF OPAC/TY AfADINGS

MIN7MUM'Ci MAXIMUM ® OBSERVER' NAME /PRINTI ' 

# nnarL
~ 

# c. ~ 

# , wesTt
~ 

# Ct
~ 

# s COMMENTS OBS ~fR ' v~ fR'S ~ SIGN

~ ` A I TURE DATE 

# l 1- 3 v - J 

# `1

. OR(' i C ~ AN! 7~ T70N 1 HAVE RfCElVED A COPY OF THESE OPACI7Y OBSERVATIONS SlGNATURE CERT7r7ED BY DAtF 0L-, T/TLf DATE - VER/F1ED BY .: DATF

~ QualirY Assurance Hendbook M9-4.2

### } 

## 4 Section 3.12.10 ~ 

### APril 1983 -
Visible Emission Observntion Form SOURCE NAMf 

## a- r) ~ j (Lti c-1 t OBSERVAT70N DATE 

## 1 l - 

## 1— - o'-d START T1ME 1 

## L20 STOP TIME 

# 1 ° 2 f 6- ADDRESS

~ j



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0 15 30 45 

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### ~ (.~ ' ~ .~ 32



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. 6 

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# 70 ~ ~ ~ G 40 

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### 0 (Z) 53 Q Q Q 0

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M1NIMUM MAXIMUM C) OBSERVER'S NAM£ (PRINTJ 

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### vL , . 

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### I L- 

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. ORPANIZATION 

### C./L I/ Y ~~ l7TLa•.i ~ NiC ~ G S I HAVE RECEIVED A COPY OF Th'ESE OPACITY OBSERVAT/0N5 S/GNATURf CfRT1F/ED BY 

### ~ T . ~ DATE, 

### ~- ~ U / j

- t TITLE 

# I VER/fIED BY DATE Qualiry Assurance Handbook M9-4.2r ~ 

### Saetion 3.72.70 ~ 

### i -4. ~ ✓ { APri17983

Visible Emission Observation Form SOURCE NAMf 'o ^ n i c ~ v4 ✓
~ J /

~ OB$'RVA T/pN DA O Tf . / („ 1

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### An A n Z0 _ EU I U 

## LG COMMfN7S OBSERVER'S SlGNATURF ~ T DATE 5 6.. 0 s OR(' ,AN17AT10N
~ w ✓
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. VERIFIED BY
. DATf
QuelltY Arsurance Hentlbook M9-4.2

# !1 Claytotri

APPENDIX E GRINDING AND PRODUCTION RATES DURING TEST PERIODS

# Ha.nson BrIlek-Stanton

Testing Performed on Grinding Room Dust Collector 11/30/04 10:00 a.m. thrrough 4:30 p.m,
The grinding operation ran at fulY production the full time that the test was being conducted. Tonnage of material that was ran t_hrough the system; Enough material to make 21 cars of brick at 26,369 Ibs. per car, 21 x 26369 =5537491b. or 276.87 tons. This weight is as ran through the system, not after the moistare is removed.0 

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APPENDIX F OBSERVER'S USEPA METHOD 9 CERTIFICATION LETTER

# ~ •

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Jyeafn2(s
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# ,u ~ , mef the specifications of Federal Reference Method 9 and qualified as a visible emissions evaluator. Maximum deviation on white and black smoke did not exceed 7.5% opacity and no single error exceeding 15% opacity was incurred during the certification test conducted by Eastern Technical Associates of Raleigh, North Carolina. This certificate is valid for six months from- date of issue.

' 32327/ ~ 

### qe6i,Q

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### &41 6, 2004 CertlBcate Number LocaBon , Date of Issue



### President Director of Training