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 for 

this 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 
/1Claytori 

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 constant 

weight 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 sampling 

probe, (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 
'1Claytorri 

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 rtieulate Cfsncentrat ~ a.n: ; , 

1b/1000 lb (dry) 0.000348 0.001426 0.000348 0.000707 

T 

 uraf kr. j, rffeuj 4 

Eii3 issran 

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 

T PmjeaNO.30.0301E.00 
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 

Vacuum 

Gauge 

Figure 3 , i i Hanson Brick 

USEPA Method 17 Sam lin ~ ~laytori P g Hanson Brick T 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 

. Pfant L!f;IV 5 L4"✓ 6'1 c k—' Run No. (~!'t~~ r, Operators f'-F'G} ' /Yl (.i) 

. Date 1' 0-0q Time ~ . ~%~~ Pitot tube nun iber 3 !'r 

Sampfin g Location _~iaq li5jJJ c Jwt /rL /

1 

Pitot tube factor, Cp - b`!i 

Stack Dimensions - Distance A Cyclonic Flow Check '"~ 

Stack Dimensions - Distance B Bar. Press. in. H;. OR_ 

Stack Dimensions- inches ~~ ` _ Area, Sq F't Static Press, in. H20 — 

- Stack Dimensfons Moisture, v/v 

_ Gas Temp., °F R+B % CO2 % CO 

Gas Temp., °F DB % 02 % N2 

TRAVERSE 

POINT 

YUMBER 

VELOCITY 

HEAD 

(LP) in.H2O 

STACK 

TEMP. 

'F 

_ 

-&EL. I-IEAD 

(OP) in.H2O 

Nu1lAngle 

(zero AP 

angle) 

FlowAnLle 

e(90' from 

null Anele) 

2. 'f SS ~ 3. s~ 2.5 I s I 

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Average 

Ps = Pbaz + (Pstat/13.6) Md-0.440(%CO2) + 0.320(%02) + 0.280( 0/.1\1 2 + %CO) 

 Ms=(Md)((1-(Bw/100))+18(Bw/100)= 

Vs = 85.49 (60) (Cp) qAp ave ( ,\ITs avg/PsMs) = fpm 

Qs = Vs As = cHn Qstd = Qs (528,7s) (Ps/29.92) = scfm 

0 1(. 

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Qs = Vs As = 

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D"I s 

3 ( '4 
A Claytoii 

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 

CASENARRATIVE 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 

ANALYTICAL 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 
,AClaytori 

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) 

818 
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/alClaytori 

APPENDIX C 

USEPA 1VIETHOD 5/17 AND 26A CALIBRATION DATA SHEETS 
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N R = O O - 
CHITEt3IA CFiECKLLST 

PITOT TUHE NUYlBER 

DATE o 4 

Pitot Tube not on Probe 

3/16 6 Dt L 3/8 

.48cm .95cm 

Pa = PH 

1.05 Dt L P,p 1.5 Dt 

d I and ct2 < 10 0 

Operator 

A

~ l 

. ~ g ~ , 

~ . ! • 

~L~v 

PA ~& V 

Pg YE v, 

• ~ v~ 

cC C v( 

s ._ , a ° 

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,9cy3t VC 

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 

11 • . ...... ~ .. p 

T ..Zt'o..... .w.... ~ r.r. 

f ~r.......n. -~~ 

tl...~ ~ x ? 1.9 em ~ i~.•~ : 

_.... 

z ~ l.ocn 1 .• .. ~ _ ~...,. 

w 7.62 cm "- 

= 

i 

F.G. B' ~ F.c. 8•2 

B-?. E ? 5.08 cm 

a i q r*ntwrninta ~ ) 

C. Y? 7. 5 2 cm 

~ ~71~ I 

f.• w 

A . 

B-1 

or 

A. YES VO 

B-+ YES VO 

8-L YE5 N0 

(: YE° `0 
CRITEz`tIA CFiECXLLST 

PITOT TUBE NUI7BER 1T+ 

DATE ✓~ w 

Pitot Tube not on Probe OQerator 

. ~. ._ ..~. 

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

Pa - P H B Pg YE5 Nc 

1.05 Dt 4 P,~ 1.5 Dt 

. . .. YES V( 

d 1 andd2 < 10° YE5 YC 

 . . . 

. ~• = . - 

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~ z a YES vG 

~~~• 

w G 0.08 cm (1/32 in) B w YE5 y0 

, ia ----_ ~.._ 

Pitot on Probe Pitot Tube Correction Factor 

Comoonent Spacing OK . ......... 

..r•....._ .«....._.,.. 

f....r 

fG.rC ~ 

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B-l. z_'.9 c:n 

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or FrG. B' ~ F.c. 8•2 

8-2. E ? 5.08 cm 

 ~ 4 nwtwrttny 

C. Y >_ 7.82 cm ~ B-Z~~ N O 

1-11 7 I

_ 

, 
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,-/ 

T~. . 

..LPA YES Nc 

Operator 

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..rTPitot Tube Correction Factor 

~ ; . ......... CD 

~~ ......_ .«....._.... 

!

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w YE5 N, O 

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YES N( 

d YES YC 

,B YES NC 

FF. ~ 

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~ F.c. B•2 

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rntttrtDTtta 

, 

. 

y~ . 
~ 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,7l~/ 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 ~ ` ~ 

PHONE 3 O ~ D 33 I G Q G f 4 p ~J 

~ b Y'7 b s - 

C 

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 

DESCR7BE E 7SSION POINT (J ~ 

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, 

D/STANCE FROM OBSERVER Cl 

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 

fMlSS/ON COLOR 13 I o ~ ~ (~ 43 d b (] I D 

START N!,',a STOP 

PLUME 7YPE C41NT7NUOUS 17 

FUG7T/VEC 7NtERM7TTEN7 ❑ 14 ~ G (7 (~ 44 t I(7 r' .~ 

l v 

WATER DROPLETS PRESENT 

 NO~T YESO 

1F WATER DROPLETPLUME. 

ATTACHED O DETACHED ❑ 

75 ~ O I Ur Fl 

V 

45 

POlNT /N THE PLUMf AT WH7Ch' OPAC7TY WAS DETERMINfD 16 G Q I Q I O 46 Q ® ® Q 

START c`^'Ld"^. :"I"".~ 'zt-STOP '*A +v ~ {— 17 0 O I o Q7 V C O o 

DESCR/BE BACKGROUND /' 

START .5 ~~~./c >z~ =fl hA ~STOP ,5'A'.-c b. 

7 8 G a 0 0 , 48 [~ ~~ 

79 ~` I ~ 0 49 C7 p® ~ ~ . 

 BACKGRDUND COLOR ~ o 

START 1 r"`r STOP JV1-~- 

SKY COND/TlONS 1 w ~Lq ~.r+ 

STAR7( ~ l/~ ?US,$T P ~~ 20 O I 0 O O 50 ~J I '

* G 

!n 

V 

 WlND SPFED 

START ~ STOP ~dw„~, 

WIND DIRECTION 

START y✓~-",STOP , 

21 Q 1 , 0 O O 5t I Q D! O o 

12 0 I O 

a O 52 (~ `J 0 AMB/fNT TEMP 

START S S STOP .jA+^^ 

WET BULB TEMP RH.Percenr 

13 D ~j I D ~ - 53 !~ ci a ~ 

S urce Leyoul ke+Ch ~ a..l o rrow 

i P .X.f rss.on ~ omr 

! ~ 

Sun-~ Wrnd — 

. 

.. 

P/ume end = Observers Posemon 

. Steak h 

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 I o 

27 0 o ; ~J D 57 0, C) CJ © 

28 C`

j ~ ® D ~ 58 < .7 © 

2s 0 0 O (i 59 3 :i C7 r7 

30 O (~ C7 Q 6D 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`ITURE 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 

1L20 

STOP TIME 

1 ° 2 f 6- 

ADDRESS ~j 

Y

n

' U`D~ ySEC 

M1N 

- 

0 15 30 45 

SE 

M7 0 15 30 45 

20~ ~a ~.r~, G ~;~ ~w ~.~ 

1 "1 

~ ~ 

31 

~ V 

C/TY ~ STA7f ~- Le ZlP, ~ 2 ~ (.~' ~ .~ 32 

~ ~/ ~~ I _® PHO pf 7 l ~ `ts 

b b 

SOURCE ID NUMBE -R ' 4 ~ 

® ~ V Q ~ V 

PROCfSS EQUIPMENT t~ 

~.r

, .'~.(.~ d`~ JC~,t-¢~L,r~ 

OPfRATING MODE ~ 

 5 ® © 

~ r.-~ 

~J O 35 U 

~»t 

i V 

», 

V 

/^ 

li' 

CONTROL EQU1P ENT 

t~ Z. i,'J1/S-Iki 

OPERATING MODE 

. 

6 © 0 U 36 0 U `; 

DESCRIBE EMISSlON PO1NT 7 o G7 Y ~ 37 ~ ~ nj t„1 

START T'J I~A^ B~'a' STOP B E) Q 38 

HfIGHT ABOVE GROUND LEVEL 

START -1-10 STOP 

HEIGHT RELATIVE TOOBSERVER 

START cl, <3 STOP 

y 

V 70 

DlSTANCE fROM OBSERVER ~ ~ ~ G 40 o O 

START ^-(tp iSTDP 

DfRECT/ON FROM OBSERVER 

START ~,: STOP 11 L9 O ~ ~ I 47 o ® ~ t7 

DESCR/BE EMlSS/ONS 

S TA R T / ~ ,I.:r STOP 

12 Q © I© 0 1 42 

73 ~ 

~ 

I v ~ G 43 ~ C7 ~ ~ EM7SS10N COLOR 

START 6vIA STOP 

PLUME TYP£. CONT/NUOUS ❑ 

FUG7TlVE C 1NTERM/7TENTO 14 ~~(~ © .0 44 O (D 

WATER DROPLETS PRESENT 

N0'k YE.SJ 

!f WATER DROPLET PLUME. 

ATTACHfD O DETACHED ❑ 

15 (Tj C I(Aj C) 45 0 Q O 

i6 

~ ~ I ~ ~ d6 ("~ (~ o ~ PO/NT 1N 7HE PLUME AT WHICh' OPACITY WAS DfTERMlNED 

START S ° '~ ry,,. ~` d'~STOP 17 0 C) Q 47 0 G 

DESCRIBE BACKGROUND 

STAR7 ~L ~ Lli~ ~,t STOP 

18 C) (D 411 O Q 0 

79 

- 49 ~ 0 Q Q Q 

 BACKGROUND COLOR 

S7ART ~; STOP 

SKY CONDlTlONS 

START EA1-~ TOP 20 ~ I~1 o Q 50 o Q Q 

W1ND SPfED 

START O STOP 

W1ND DIRECTION 

START NA STOP 

21 © i o I O 51 O O O O 

Z2 ~ I © Q ~ 52 Q 0 I~ Q 

AMB7ENT lEMP 

S7AR7 S70P 

WET BULB TEMP. RH.percent 

23 0 (Z) 53 Q Q Q 0 

. SourceLeroutSkelch cr ~w rrow 

I 26 

mis5ian ➢ f ~~/ 

I 

Sun~ Wmtl — 

P/ume sntl = Observers Posmon 

Sreck 

740'Y 

_ 

Sun Locarmn L'ne ' 

24 F') 54 ~ 

25 I`(Y` („n r (j 55 (j O . ^~ U^ 

~ C) ( d 56 fl Q (} 

27 ~ C" 0 ~7 57 O O o O 

28 (~ (j C~ ~j 58 ~ o 

29 (`) ~ ~} ~J' 59 6 Q ~ Q 

3D ~ 

n (J ~+, V 60 O _ o O ~ 

AVfRAGf OPACf7Y fOR ^ 

HIGHEST PER70D 

NUMBER OF RfADINGS A80V£ 

 d % WERE b 

RANG£ OF OPAC/TY READINGS 

M1NIMUM MAXIMUM C) 

OBSERVER'S NAM£ (PRINTJ 

Ytnu.+:v( ~ L✓ZS ~~ ~(t~ 

COMMENTS 08SERVER'S SIGNAT R 

vL,.~,/L 

DATE 

 I L- ~ o~ d Li 

. 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 M9-4.2 
r ~ 

Saetion 3.72.70 ~ i -4. ~ ✓ { APri17983 

Visible Emission Observation Form 

SOURCE NAMf 'o^ n i c ~ 

v4 ✓~ J ~ /

OB$'RVA T/pN DAOTf . 

/ („1/ 

START T1Mf

6 

STOP~TIMfO 

ADDR£SS 

M1N 0 15 30 4$ Ml 0 I 75 30 45 

1 v I O 6 0 ~ 37 

CITY 

~ 

STATEL 

l~ 

Z!P ^ ~ 2 O 6 ~ Q 32 I ~` ~ o Q 

3 ~ I ~ v (`~j I 33 I ~ d V PHONE 

66 6 ~-6 3-1-1 ~~-5 

SOURCE 1D NUMBER 

4 D`J 34 ~~~7 

I (~ 

U 

PROCESS EQUIPMENT 

~'r_..-...C ~ --, ~S'. ~Cr•LZr„ 

OPERATING MODF 

5 O C7 35 

CON7RO~fQU1PME T 

'TC 

OPERATING MOD£ 6 0 ~ 

T ~ ~ ~ 

~j 

DfSCRIBE EM SSlON POINT I V 37 ~ C7 

START rz~ e,1,4 STDP b 38 0 I p 

HElGHT ABOVE GROUND LEVEL HEIGHTRELATn/E 700BSERVER 

START "`IO 7 STOP START -AS' ' STOP 

y 6 Q b 

10 O O I ~ Q 40 DISTANCE FROM OBSERVER DIRECTlON FROM OBSERVfR © 6 0 

START STOP ISTART ~rj' E STOP 71 O I0 ® 41 

DESCRlBF FM1SS/ONS 

STAR7 ~a f~ STOP 

72 ~j r^ V ~ (7 42 

13 I (~ b (~ 43 U ~ G EMlSS/ON COLOR 

START / ~ /pl~ STOP - 

PLUMf TYPF. CON77NUOUS ❑ 

FUGlTIVEC INTERM/TTFN7 ❑ 14 p ~ O ~ 44 

WATER DROPLETS PRfSENT 

NO ~i YESO . 

IF WATER DROPLET PLUME 

ATTACHED ❑ DfTACHED O. 

15 'G' ~ I O O 45 ~ b ~ ~ 

76 Q © I ~ p 46 ('f ~ U O POINT IN~l7Hf PLUME AT ,kWH/CH OPAClTY WAS DETERM/NED 

START y L~ •rn, i` ~"~S70P 17 Q V (~ ~J 47 (7 0 ~ (~ 

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START I~~ .^,<-'`v.~,LI STOP 

78 Q p Q f~ 48 © ~ b 0 

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START ,'"'~ STOP 

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START ~""^ySTOP 20 I I 8 C% 50 (rJ ~'J o o 

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START STOP ~ 27 i. - 0~ O '' S/ ~ 0 0 

22 p I ~ ~ d 52 ~ o O 0 AMBIENT TEMP 

START ~ O STOP 

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23 O Q (, 53 ~ ~ (~ Cj 

Source Layoul Sketch Drew North Arro ~ 

Sun~ W.ntl.. 

on P/ume an0 = 

Sreok 

7 

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- 

24 p O C7 O_ 54 ~ C~ 6 0 

25 p Q p 55 

26 ~J ~ © ~ 56 O ~ b O 

27 O O U 5T 0 0 

28 l~ p (~ 58 0 

29 Q o ~ ~ 59 o C) Q 

30 (.'~ Q (3 © 60 ~ Q p 0 

AVERAGE OPAC/TY FOR ^ 

HIGHEST PER10D ~s 

NUMBFR OF READINGS ABOVE 

~ %WERE 

RANGE OF OPAC/TY READINGS 

MINIMUM O MAXIMUM Q 

OBSERVER'S NAME (PR1NT/ 

An A n Z0 _ EUIULG 

COMMfN7S OBSERVER'S SlGNATURF ~

T 

DATE 

5 6.. 0 

s 

OR(',AN17AT10N 

~ w ✓-~-~ ~ ✓l-aL ' f~ V i ~ .-,1 

7 HAVE RECF7VED A COPY OF THESE OPAClTY OBSERVATIONS 

S/GNATURE 

CERTIFIED BY t- DATE 

G T Ia 

TITLE DATF . 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 z 

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APPENDIX F 

OBSERVER'S USEPA METHOD 9 CERTIFICATION LETTER 
~ •

~~lrxz/v °Jyeafn2(s~,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~;fi, /adi%cd.crrU Od,o~&41 6, 2004 

CertlBcate Number LocaBon , Date of Issue 

President Director of Training