FROM.:TAYLOR

CLAY FAX NO. :7046362413 San. 28 2009 04:41PM

P1 •1 • I •oo7 Taylor Clay

Products, Inc.

P. O. Box 2128, Salisbury,

North Carolina 28145-21•8 185 Peeler Rd. •8147

Phone (704) 636-2411 taylor•taylorclay.com Fax (704) 636-2413 www, taylor¢lay.eom FAXRTZ Pages:

Phone:FROM

:TAYLOR

CLAY :?046362413 Jan. 28 2009 04:41PM

P2

ENGINEERINQ CONSLILTANTS,

INC.,
Blvd. Oharlotte,

NO •8=69

|704) 5•8-1049

FAX (?04) -•98-1050 August l 8, 2000 Mr. H•oM Howard Plant Enginecr Taylor Clay Products

Company Post Office Box 2128 Salisbury, North Carolina

28145 Stack Emission

Testing Services Taylor Clay Product

Company Salisbury, North CaroIina Trigon Project No. 046-00-076 Dear Mr. Howard: Please find enolosed

a copy of the "Summary

of Results",

field dam shoots, laboratory analysis, and the production

data for thv hydrogen

fluoridv

(HF), and sulfur dioxido

(SO2) testing conducted on July 11 & 12, 2000 at the Taylor Clay Products

facility in Salisbury,

North Carolina. Testing was conducted

on the limestone

scrubber

exhaust for concentrations

and ¢missions

rates of I-IF and SO2. Three 3-hour sampling

runs were conducted

at the svrubb•r

exhaust. Thank you for the opportunity

to provide

this servico to you. If there are any questions regm'ding the sampling

procedures

or data generated

fi'om this project,

please do not hesitate

to contact me.

RFC:mos Enclosures Sinc•ty, TRIGON

ENGINEERING

CONSULTANTS,

INC.

Robert F. Callahan Project Manager Air Monitoring

DepartmentFROM

:TAYLOR

CLAY FAX NO. :7@46362413 5an. 28 2009 04:41PM

P3

Run Number Date: 0Pb•r

EPA METHOD

26A Detorraination of Hydrogen

Fluoride

Emissions Taylor Clay Products Salisbury, North Carolina Limestone Scrubber

Exhaust

I

2

3

Avg 07/11/00 07/12/00

07/12/00 180.0 180.1

180.0 29.12 29.15

29.18

29.15 Net Time of T•st, minutes Barometric Pressure,

in. Hg PgPsV•

/Sl"O
Vwc

%Oi%CO• %COM•CpAPSTsV•A Static Pressure,

in. Hg St•ck Pressure,

Absolute,

in. Hg Actual Meter Volume

Sampled,

cu. ft. Avg. Delta H, in. H20 Avg. Gas Meter Temp., Dog. F Volume Sampled

at Stand. Con&, cu. ft. Volume of Water Collscmd,

rnl Volume of Water Vapor at St& Cond.,SCF Moisture Conmnt

of Gas Stream Percent Moisture

in Stack Mole Fraction

of Dry Gas Percent Oxygen,

Dry Percent Carbon Dioxide,

Dry Percent Carbon Monoxide,

Dry Mole. Wt. Stack Oas, Dry Basis, lb/lb mole Mole. Wt. Stack Gas, Wet Basis, Ib/lb mole Pitot Tube Constant Avg. Sqrt. Delta P, in. H20 Avg. Staok Temp., Deg. F Avg. Sta•k Velooity, Area Stack, -0.019

-0.019

-0.019

-0.019 29.I01 29.131

29.161

29.131 168.02 161.82

165.82

•65.22 2.55 2.38

2.48

2.47 85,2 80.5

80.8

82.2 159.39 154.93

158.87

157.73 338.7 340.4

332.8

337.3 15.95 16.03

15,67

15.88 0.091 0.094.

0.090

0,092 9.1 9,4

9.0

9.2 0,909 0,906

0,910

0.908 I6.63 16.64

17.02

16.76 2.49 2.58

2.34

2.47 0.00 0.00

0.00

0.00 29.064 29.078

29.055

29.066 28.057 28.040

28.063

28.053 0.84 0.83

0.84

0.84 0.463 0,477

0.468

0,469 405.3 408.9

405.9

406.7 34.3 34.9

34.6

34,6 12,048 12,048

12.048

12,048FROM

:TAYLOR

CLAY FAX NO. :7046362413 Jan. 28 2009 04:42PM

P4

;;-:,•

;L}"

••:•"..,.':...'22.•,.....: EPA M•THOD

26A .Determination of Hydrogen

Fluoride

Emissions Taylor" Clay Products Salisbury, Not• Carolina Limestone Scrubber

Exhaust

29,101

159.4
15,95

0.091 •lack Pressure,

Absolute,

in. Hg l• Pb,, + P• Volume Sampled

at Stand. Cond., cu. ft. 17.647 * VM * (Pb,, + AH / 13.6) Tu + 460 Volume of Water Vapor at Std. Cond.,gCF Vwc 0.04709

* Vc Moisture Content

of Gas Stream Vw• Vs• + Vwc l•eent Moisture

in Stack 100 * Vwc Vsvo + V• Mole Fraction

of Dry Gas 100 PMv I00 Mole. Wt. Stack Gas, Dry Basis, lb/lb mole M• 0,44 * %CO• + 0.32 * %02+ 0.28 * (100 %COu

%02) Mole. Wt. Stack Gas, Wet Basis, lb/Ib mole Ms Me * (1 Bw.) + 18.0 * B,•, -- Avg. Stack Velocity,

ff/seo

(Ts + 460) Vs 85.49 * Cp * APS * SQRT

............... (Ps * M,) Gas Volume

Flow, Dry Std. Cond. CFM 1058.82 * V.• * A * Ps * (I B,•) Ts + 460 9.1

0.909

29.064
28.057
34,3

13358FROM

:TQYLOR

CLR¥ FRX NO. :7046362413 San. 28 2@09 04:42PM

P5

EPA METHOD

26A Determination of Hydrogen

Fluoride

Emissions Taylor Clay Products Salisbury, North Carolina Limestone Scrabber

Exhaust Gas Volume

Flow, Dry Std. Cond. CFM

13358

13531 Aotual Gas Volume

Flow, CFM

24759

25237 Gas Volume

Flow, Wet Std. Cond., CFM

14694

I4931 Sample Nozzle Diameter,

inches

0.376

0.372

13514

13467 24982 24993 14847 14824 0.376 0,375 A. Area of Nozzle,

R • 0.00077 I Percent Isokineti• 103.6 :Hydrogen Fluoride

Coneentratlon

and Emission

Rate Hydrogen Fluoride

Catch, mg

149.8 Hydrogen Fluoride

Concentration,

gr/dscf

0.0145 Hydrogen Fluoride

Concentration,

gr/acf

0.0137 Hydrogen Fltmride

Emission

Rate, lbs/hr

1.66

i"

0.00075

0.00077

0,00077 101.5 102.1

102.4
155.4 166.6

157.3 0.0154 0.0161.

0.0154 0.0148 0.0155

0.0147 1.79 1.87

1.77FROM

:TAYLOR

CLAY FAX NO, :7046•6241• 5an. 28 2009 04:42PM

P6 SUMMARY OF RESULTS EPA METHOD

26A Determination of Hydrogma

Fluoride

Emissions Taylor Clay Products Salisbury, North Carolina Limestone Scrubber

Exhaust i•.i! Signal Gas Volume

Flow, CFM i';"• Vs * A * 60 i!..'i•."• Volume

Flow, Wet Std. Con&, CFM '?:•. Q,D* [1/(l-Bw,)] •" i' i:.•.'i,,:.• of'Nozzle,

f•

0.0945 * (Ts + 460) * Vsvn

Fluoride Concen•tion,

•/dscf

S•d•d Conditions) 24759
14694

103.6

0.0145

0.0137

1.66FROM

:TRYLOR

CLRY FRX NO. :7046362413 Zan, 28 2009 04:42PM

P¥

Net Time of Test, minutes Barometric Pressure,

in. HgEPA METHOD

6C Determination of Sulfur Dioxide

Emissions Taylor Clay Products Salisbury, North Carolina Limestone Scrubber

Exhaust 1 07/11/00 180.0 29.12

2 07/12/00 180.1 29.15 -0.019 29,131 161.82 2.3880.5 154.93 340.4 16.03 0.0949.40.906 16.642,58 29.078 28,040 0.830.477 408.9 34.9 12.048 %0=%C0• MaMsCpAPS

A Static Pressure,

in. Fig St/•ok Pressure,

Absolute,

in. Hg Actual Meter Volume

Sampled,

eu. ft. Avg. Delta I-I, in. I-lzO Avg. Gas Meter Temp., Deg. F Volume Sampled

at Stand. Cond., eu. ft. Volume of Water Collected,

ml Volume of Water Vapor at Std. Cond., SCF Moisture Content

of Gas Stream Percent Moisture

inGas Stream Mole. Fraction

of Dry Gas Percent Oxygen,

Dry Percent Carbon Dioxide,

Dry Mole. Wt. Stack Gas, Dry Basis, llglb mole Mole. Wt. Stack Gas, Wet Basis, lb/lb mole Pitot Tube Constant Avg, Sqrt, Delta P, in. HaO Avg. Stack Temp., Deg. F Avg. Stack Velocity,

R/see Area Stack, • -0.019 29.101 168.02 2.5585,2 159.39 338.7 15.95 0.0919.10.909 16.63 2.49 29.064 28.057 0.84 0.463 405.334.3 12,048 3 07/12/00 180.0 29.18 -0.019 29.161 165,82 2.4880.8 158.87 332.8 15,67 0.0909.00.910 17.022,34 29.055 28.063 0.84 0.468 405.9 34.6 12.048

Avg

29.15 -0.019 29.131 165.22 2.4782.2 157.73 337.315.88 0.0929.20.908 16.762.47 29.066 28,053 0.840.469 406.7 34.6 12.048FROM

:TAYLOR

CLAY FAX NO. :7046362413 Jan. 28 2009 04:42PM

P8
EPA METI•, OD 6C Dotermination of Sulfur Dioxido

Emissions Taylor Clay Produots Salisbury, North Carolina Limestone $¢rubbor

Exhaust Qm Gas Volume

Flow' Dry Std. Cond. CFM Q• Aotual Gas Volum©

Flow, CFM Sulfur Dioxide

Concentrations

and Emission

Rates Cm• SO• Concentration,

ppm dry Cd SO2 Concentration,

ibs/dsef 802 Emission

Rate, lbs/hr CAw 13358

13531

13514

13467 24759 25237

24982

24993
68.50 0.000011 9.11 65.03

53.27

62.27 0.000011 0.000009

0.000010 8.76 7,17

8.35FROM

:TAYLOR

CLAY FAX NO. :7046•6241• San. 28 2009 04:4•PH

Pg

SOURCE DESCRIPTION Taylor Clay Products,

hac. operates

a brick manufactttring

facility at 185 Peeler Road in Salisbury, North Carolina.

The company

has been .at, its current location

for more than fifty years and has ff•ee natural gas-fired

kilns that are utilized m drying product.

A fourth kiln was recently

built and brought

on-line.

Testing w•s conducted

only on the new kilr• while burnin• a mixture

of Petroleum

coke and natural gas. Bdck Kiln #4 (ES-K4-rated

at 16 mmBttVhr)

utilize eomp_uter-eon_tro!!eaw_•,ab!e •,**,• *-•,,, draw flue gases from the tunnel to maintain

a constant

pressure

in the firing zones. A limestone absorber treats the gases prior to exhausting

to atmosphere

through

a baghouse

and then a 26" round, vertical

stack. Refer to the process sketch below.

Absorber I. D. Yah

Bagfilter w/ 2,800 •q. ft. of filter area (CD-K4-2)

Exhaus• ] St•ck
The following

table outlines

process data tracked by STACLEAN

employee

Doug Ashbaugh. pro,,cess Data

Summa Pa.ra, meter Run #1 •un #2 Lime Inection

Rate, gpm Temp. #1 inlet of Lime Injec.t!_o.n),

F Temp. •2_. (Outlet of Lime Injection)•

• Temp. #3 (Inlet of Baghouse),

F Magnahelic (Duct pressure

@ inlet to Lime Injection)

in. H=O Baghouse Pressure

Drop, in. H•O Fan Speed•

Hz 0.61 327.7 248.4 249.1 13.72 51.66

0.62 330.4 251.7 '2s0.s 1.543.71 52.71

R.,.u. n #3 0.66 327,3 2•0.4 248.4 13.68 53.54Average0.63 328.5

Mr. Steven Rlankenbeker,

Engineer

for Taylor Clay was the facility liaison during emissions testing. Mr. Blankenbeker

stated that during sampling

the kiln was processing

approximately 8,200 tons of green brick per hour (or 4,1 tons per hour) and that approximately

0.067 tons per hoar (1.6 tons per day) of peteoke

was burned. ATC Project No. P-7132 Taylor Clay Kiln. ES-K4 Page 5 of 54 52.64 1.563,70250.2 249.$FROM

:TAYLOR

CLAY FAX NO. :V046•6241• Jan. 28 2009 04:4•PM

RESULTS SUMMARY SYSTEM Taylor Clay Lime Slurry System TEST DA TE

11/01/07 PARAMETER R•l.Metsls

R#2.Metals

R#3.Metals A VERA QE GENERAL Q$• FLOW; ACFM

10,497

9,883

9,294 Q STD DRY, FLOW $CFM

5,880

6,509

6,093 %1 105.28

100.93

109.75 9,8916,494

QS, FLOW, ACFM

12,820

12,221

12,494 Q STD DRY, PLOWSCFM 6,963

6,657

6,751 %1 96.43

98.83

98.64 12,512 6,790

Petcoke Firing Rata, ton•/hr Metals Emission

Rate Summarv. PMRc (ibs/hr).As

1.31E-05 Note: 1/2 of detection limit used for run• 2 and 3. Controlled Arsenic Emissions,

Ib=/ton petcoke

2.84E-06

2.61E-06 0.067

6.17E-06 9.22E-05 PMRc (Ib•/hr).Cd

4. t4E-06

1.82E•06 Controlled Cadmium

Emisalons•

Iba/ton petcoke 1.36E-05 2.44E-06 3.64E-05 PMR¢ (lt•thr)-Aa

1.07E-03

1.51E-03

1.34E-03 1.31E-03 Uncontrolled Arsenic

Emissions,

Ibs/ton petcoke PMR•: (ib•hr).C.d

5.55E-06

7.34E-06 Uncontrolled Cadmium

Emissions,

Ibs/ton petcoke

7.79E-06 1.95E-02 6.90E-06 1.03E-04 Permitted Arsenic

Emissions,

Ibs/ton 6.58E-07 Permitted Csdmlum

Emissions,

Ibs/•on 3.13E-06

ATC Project No. P-7132 Taylor Clay Kiln E$-K4 Page 6 of 54FROM

:TRYLOR

CLRY FRX NO. :7046•6241• Jan. 28 2009 04:4•PM

Pll

SYSTEM

TEST DATE PARAMETER

RESULTS

SUMMARY Taylor Clay Lime Slurry System
11/01/07 R#1.HCI/HF R#2.HCI/HF

R#3-HCI/HF A VERA GE

I le__j FLOW, ACFM O STD DRY, FLOW$CFM%1 HCI/HF, .EmI•sion= PMRo (Ibs/hr)-HCl

10,070

10,088

10,19t 6,649 6,485

6,542 102.13 100.55

103.34 10,850 12,049

11,786 5,954 6,471

6,357 92.74 102.31

97,49

2.83E-03 Note: 1/2 of Run 2 ND used to celculate average PMRc (Ibs/hr).HF

4.481E-04 Note: 1/2 of ND values used to calculate average
PMRc (Ibs/hr).HCI

1,02E-01 PMRc (Ibs/hr).HF

1,49E+00 Destruction Efflclen.cv.

% Hydrogen Chloride

(HCI)

97=23% Hydrogen Fluoride

(HI = )

99.97% Reouired Destruct/on ETflclencv..%

7.38E-04

2,55E-03
5.49E-04 4.981=-04

1.05E.01 1.04E-01 1.57E+00 1.23E+00

99.30% 97.56% 99.97% 99.96% 10,116 6•559

11,562 6,261

2.04E-03 4,•)8E-04

1.04E-01 t .43E÷00
98,03% 99,96%

ATC Project No, P-7132 Taylor Clay Kiln ES-K4 Page 7 of 54FROM

:TRYLOR

CLAY FAX NO. :7046362413 San. 28 200• 04:44PM

P12

Results Summary

of Gaseous

Emissions

Testing

Client: Loc, atlon: Date: ,•General Stack Parameters RunTimesTaylor Clay Salisbury, NC 11101/07 Lime Sorubbar

Inlet

Start End Sta•k Velocity, feet per second Aetual VolumetfiG

Air Flow Rate, cubic feet per minute Stack moisture,

percent Staek temperature,

degrees F Standard Volumetri¢

Air Flow Rete, cubie feet per minute Oxygen Concentration,

percent (corrected per 7e-5b) Carbon Dioxide concentration,

percent (corrected per 7e-Sb) Measured Gase0u•

Po!lutan

• Sulfur Dioxide SO2, ppm vlv dry basls•correc=ted SO2, lbs/hr SO•, potential

tons par year 9:00 AM 9:59 AM

6.54 429.3 6,963
17.21
2.33

332.02 21.90 95.92

12:20 PM 1:19 PM
93.36 12,221
6.80 424.2 6,657
16.68
2.63

339.96 21.87 95.79

3:22 PM 4:21 PM
95.45 12,494
7.97 420.3 6,761
16.58
2.63

341.62 22.17 97.10

12,5127,10 424,60 6,790

16.822,63
Averane 337,87 21,98 96.27

ATC Project No. P-7132 Taylor Clay Kiln ES-K4 Page 9 of 54FROM

:TAYLOR

CLAY FAX NO. :7046362413 3an. 28 2009 04:44PM

Results Summary

of Gaseous

Emissions

Testing Client:J Location:• Date: 8our, ce: Parametem Taylor Clay Salisbury, NC 11/01/07 LIm•.$crubber Outlet

9:00AM 9:59 AM 10:59 AM

12:20 PM 1:19 PM 2:19 PM

3:22 PM 4:21 PM 5:21 PM feet per second 45.52

45.60

46.07 Air Flow Rate, 10,070

10,088

10,191

45.73

percentdegrees F 7.12 266.4 6,649 Concent/'etion, percent 16.62 7e-5b)eoncentretion, percent 2,68 per 7e-Sb) Gaseous poli0tants
v/v dry basts-corrected 215,22 ¢•s/hr 14.20 potential tons per year 62,18 Destruction/Removal Efficiency,

%

35.18%

9.37 268.0 6,485 16,72
2.54

200.12 12.87 56.39 41.13%

9.72 266.3 6,542
16.42
2.66 Run#3
187.49 12.17 53.29 45.12%

8.74 266,•}0 6,S•9
16.59
2,63

200,94 13,08 S7,29 40.48% Removal Efficiency,

%

ATC Project No. P-7132 Taylor Clay Kiln ES-K4 Page 10 of 54FROM

:TAYLOR

CLAY FAX NO, :7046362413 Jan. 28 2009 04:45PM

P14

RESULTS, CONCLUSIONS AND COMMENTS
Results from the destruction

efficiency

testing of the Lime Slurry Injection

System are presented .• •he preceding

test summaries.

Additional

information

can be reviewed

in the Caleulatlons

and Aplxmdix sections

of this report. Stack Profile-Inlet M¢•als Train .Slack velocities

were measured

at a mean 95.58 feet per second (Ft/s) with the metals sampling •nin. This yielded a mean actual volumetrle

flow rate of 12,512 cubic feet per minute (acfrn). :Standardizing the volumetric

flow for temperature,

moisture

and pressure

yielded a mean value Of 6,790 cubic feet per minute (scfm). I•CH'IF Train .S•aek velocities

were measured

at a mean 88.33 feet per second (Ft/s) with the HCI/HF

sampling •rain. This yielded a mean a6tual volumetric

flow rate of 11,562 cubic feet per minute (acf_m). Startdardizing the volumetric

flow for temperature,

moisture

and pressure

yielded a mean value of 6,261 cubic feet per minute (scfm). _S•ck Pr•lrae-Outlet Metals Train Stack velocities

were measured

at a mean 44.71 feet per second (Ft/s) with the metals sampling train. This yielded a mean a•tual volumetric

flow rate of 9,891 cubic feet per minute (aefm). Smndardizlng the volumetric

flow for temperature,

molsmre

and pressure

yielded a mean value of 6,494 cubic feet per minute (scfm). .FI.C1/HF Tr,•n Stack velocities

were mcas•ed

at a mean 45.73 feet per second (Ft/s) with the HCI/HF

sampling L,-ain. This yielded a mean actual volumetric

flow rate of I0,116 cubic feet per minute (acfm), Standardizing the volumetric

flow for temperature,

moisture

and pressure

yielded a mean value of 6,559 cubic feet per minute (scfm), Benzene Results Benzene mass rates were calculated

utilizing

the volumetric

flow rates determined

by the HC1/HF sampling

trains for each loeatiort.

Benzene

was not detected

on any sample,

inlet or o•atlet. Therefore

mass rates were calculated

utilizing

1⁄2 of the detection

limit of the an•alys{.s. .ATC Project No. P-7132 Taylor Clay Kiln ES-K4 Page 11 of 54FROM

:TAYLOR

CLAY FAX NO. :7046362413 Jan. 28 2009 04:45PM

PI5

RESULTS, CONCLUSIONS, AND COMMENTS (continued) yielded a mean benzene

mass loading rate of <4,99e "•4 lbs/hr and a benzene

emission

rate of "•.220e • lbs/hr. Based on a petcoke

usage rate of 0,07 tons/hour,

the mean specific

emission •¢•e of 7,77e "°3 lbs/hr is in compliance

with the permitted

allowable

of 0.0303 lbs-benzene

per i•: •n of petcoke

burned. Hydrogen. chloride

and hydrogen

fluoride

concentrations

were detectably

present in all inlet samples. The calculated

mean mass loading rates were 1.43 lbs/hr of I-IF and 0,104 lbs/hr of HCI. HC1 concentrations

were detectable

on two oft.he three outlet samples.

To calculate

a mean estinaated

emission

rate, 1⁄2 of the detection

limit was utilized for run two. This yielded mass HC1 emission

rate of2,04e "°3 lbsMr yielding

a removal

efficiency

of 98,03%,

in corripliance with the required

removal

efficier•ey

of 95%. Hydrogen fluoride

concentrations

were not detected

in any of the outlet samples;

therefore, emissions for each of the three runs were calculated

utilizing

1⁄2 of the detection

limit of HF, This yielded an estimated

mass emission

rate of4,98e -°• Ibs/hr and a removal

efficiency

of>99,96%, HF removal

efficiency

is also required

to meet 95% as stipulated

in the facility air permit. Metals Mass Rate•,, Arsenic and cadmium

concentrations

were determined

on both the inlet/exhaust

via US ]SPA method 29 sampling

trains. Arsenic

mass loading prior to the bagl•ouse

was 1.3 le "°• lbs/hr. Arsenic was only detected

ir• the outlet sample on run one; the arsenic mean mass emissions

were calculated utilizing

the mass rate of run one and the mass rates of runs two and three, which were calculated utilizing

1⁄2 the arsenic detection

limit. The Kiln #4 arsenic emission

rate of 6.16e "°6 lbs/hr was slightly in excess oft he fuel-based

emission

standard

of 6.5 8e -°7 ibs/hr. Cadmium inlet mass rates were a mean 6.90e "°• Ibs/hr compared

to the exhaust rate of2,44e "°e lbs/b_r. Controlled

emissions

were less than the fuel-based

emission

standard

of 3.13e -°eIbsarsenic per hem', Sulfur Dioxide

Mea•.urements Sulfur Dioxide

(SO2) concentrations

were measured

continuously

on the inle• and exhaust of the lime injection

system.

Inlet concentrations

averaged

338 parts per million which yielded a mass loading rate of 21,98 lbs/hr and a potential

uncontrolled

emission

of 96.3 tons per year. Exhaust concentrations averaged

200,94 parts per million yielding

a controlled

$O• emission

rate of 13,08 lbs/hr, The potential

SO• emissions

from. the #4 Kiln are projected

at 57,29 tons. Removal effieiencies averaged

40.48%,

less •an the permit-required

efl'ieiency

of 95%. ATC Project No, P-7132 Taylor Clay Kiln ES-K4 Page 12 of 54