From: Schimmel, Terry (Bricks - Phenix City) <Terry.Schimmel@boral.com>

Sent: Wednesday, October 31, 2012 10:55 AM

To: Telander.Jeff@epamail.epa.gov

Cc: Keith Barnett <barnett.keith@epa.gov>; Raymond, Gabrielle <graymond@rti.org>; 

Marinshaw, Richard <rjmarinshaw@rti.org>; Holloway, Thomas C. (Tom) 

<tcholloway@rti.org>; Sroka, Kristin <ksroka@rti.org>; Susan Miller <SMiller@bia.org>; 

Keon, Mary Ann (Industries - Atlanta) MaryAnn.Keon@boral.com

Subject: If RE: Clarification of Production During Testing at Bessemer, AL

Jeff,

Sorry for the confusion and I thought we had the reports corrected but apparently not. The 

configuration of our DIFF and the reporting criteria of the ERT plus some of the learning curve on the 

testers part in reporting the data has been a challenge for all. Anyways here are the answers that 

hopefully will clear things up:

1. All of the dryer data is correctly reported at an approximate 12TPH throughput. We have 4 

tunnel dryers that are paired into two exhaust ducts. We tested only one as the sources are 

identical. Each pair of dryers feeds one of the two tunnel kilns.

2. All the DIFF data is outlet and represents a throughput of approximately 24 TPH. There is 

only one DIFF outlet stack and all of the flow from the two kilns exits via the scrubber and 

through that stack. Both kilns were operational and at the 12 TPH/each capacity during the 

test.

3. The confusion on the reagent feed rate originates from the fact that there are separate 

inlets to the DIFF from each individual kiln. Each inlet has a reagent feed system and at the 

time of the test each was feeding 72#/hr or a combined feed rate of 144#/hr. That said if it 

matters the 72# feed rate equates to a 12 TPH throughput of product.

Please let me know if this addresses your questions.

TERRY SCHIMMEL

V.P. Technical Services

Boral Bricks Inc.

Office: (334) 480-2488 

Mobile: (706) 575-6213

Fax: (334) 291-9627

Email: Terry.Schimmel@boral.com

100 Brickyard Road Phenix City Alabama 36869

http://www.boralbricks.com

http://www.boralbuildingproducts.com
From: Telander.Jeff@epamail.epa.gov [mailto:Telander.Jeff@epamail.epa.gov] 

Sent: Tuesday, October 30, 2012 8:47 AM

To: Schimmel, Terry (Bricks - Phenix City)

Cc: Keith Barnett; graymond@rti.org; rjmarinshaw@rti.org; tcholloway@rti.org; Sroka, Kristin

Subject: Clarification of Production During Testing at Bessemer, AL

Hi Terry,

While reviewing the files submitted by Boral Bricks Bessemer, AL (BORA-5) Plant 6, we noticed a 

potential discrepancy that needs clarification. The 114 information request specified that Boral Bricks 

test the Bessemer, AL Plant 6 DIFF Stack, which controls emissions from two kilns (003 and 

004). However, upon review of the test report and ERT file from the July 13-15, 2010 test, it is unclear 

whether one or both of the kilns that are ducted to the DIFF were actually operating during the testing. 

We initially assumed that both kilns were operating during the testing because they both are ducted to 

the DIFF and the test report does not indicate that only one kiln was operating. (In the process 

description section, there is only a statement that the process description was not provided (for some 

reason this page is only in the hard copy and was left out of the PDF).) The test report provides the 

production rate for each run in several places (summary tables in the hard copy, also page 68 of the 

PDF), but it never specifies if that is the total for both kilns or just one kiln, so we assumed that both 

kilns were operating at about 50% capacity. The production rates in the test report are listed below: 

Run 1 = 11.99 ton of Fired Brick 

Run 2 = 12.40 ton of Fired Brick 

Run 3 = 12.40 ton of Fired Brick 

When we compared the test report with the ERT file, we noticed a few things that made us question our 

original assumption. Although the ERT does not clearly state if both kilns were operating or if only one 

was operating, the ERT file includes this description of the source on page 2: 

“Two Swindell Dressler tunnel kilns controlled by an E.I. Tec Dry Injection Fabric Filter which uses 

hydrated lime as the reagent. The feed rate at the time of testing was 72 lbs of lime per hour. The 

throughput rate of the kilns is 24 tons/hr, which equates to 12 tons/hr per kilns.” 

The production rate fields in the ERT were left blank (p. 18), so we do not know if this is a general 

description of the capacity of both kilns, or a description of the actual throughput during the test. Also, 

the feed rate of lime is about half of the rate provided in the ICR response for this APCD, which could be 

consistent with either both kilns operating at about half capacity or one kiln operating while the other 

was shut down. 

Both reports are attached for your convenience. Note that the “Boral Bessemer July 2010 Test 

Report.pdf” does not include all the same pages as the hard copy version.
I would appreciate it if you would clarify whether one or both of the kilns were operating during the July 

2010 Brick MACT ICR testing. If both kilns were operating, please confirm that the production rate is for 

the sum of the two kilns. We want to make sure we have the correct number of kilns correlating with 

the reported emissions and production rates in the test report. 

Thanks, 

Jeff

Jeff Telander

Sector Policies and Programs Division

Office of Air Quality Planning and Standards

(D243-02)

RTP, NC 27711

919 - 541-5427

919 - 541-5450 (FAX)

Overnight mail address:

US EPA

Mail Code D243-02

109 TW Alexander Drive

RTP, NC 27709

2 attachments

(See attached file: Boral-Bessemer,AL-ERT-Final Test Report.pdf)

(See attached file: Boral Bessemer July 2010 Test Report.pdf)