Compliance Stack Emission 

Test Report 

Determination of Total Filterable Particulate 

Matter, Hydrochloric Acid, Hydrofluoric 

Acid and Visible Emissions 

Bickley Kiln (Source ID: 102) and Harrop Kiln 

(Source ID: 101) 

EPA Methods 1, 2, 3, 4, 5, 9, and 26A 

Glen-Gery Cornoration Mid Atlantic Plant 

Shoemakersville, Pennsylvania 

Date Conducted: October 10 and 11, 2007 

Job Number: 071008 

Prepared by: 

Air Compliance ~ 

Testing, Inc. 

PO Box 41156 

Cleveland OH 44141-0156 

Phone: (800) EPA-AIR1 (372-2471) 

Report Date: November 7, 2007 
SuperiorQuality Air Compliance 

Emission Testing. p, — (1 „ n n x 

Valid Results 

Guaranteed. "P Ukd 11;" 'I Testing, Inc. 

P.O. Box 41166 Cleveland, Ohio 44141 

1-800-EPA-AIR1 www.aircomp.com 

testing@aircomp.com 

November 7, 2007 

Jerry Carrier 

Director of Research/Development 

Glen-Gery Corporation Mid Atlantic Plant 

433 South Pottsville Pike 

Shoemakersville, Pennsylvania 19555 

Dear Jerry: 

The following report provides the results of the compliance emission testing conducted on 

October 10 and 11, 2007. These results are a product of the application of the U.S. EPA 

Stationary Source Sampling Methods listed in 40 CFR Part 60 Appendix A that were in effect 

at the time of this test. 

Please mail one copy of this report along with any other supportive process operating data 

collected during this test to your local EPA representative. You should also attach a cover 

letter (on company letterhead) stating the purpose and the outcome of this test. Additionally, 

you may address, preferably in a timetable format, any obligations or implications that might 

be necessary to achieve environmental compliance because of the result of this test. 

Please do not hesitate to call if you have any questions or concerns about these test results. 

On behalf of Air Compliance Testing, I would also like to personally thank you for the 

opportunity to work with you on this testing project and would enjoy the opportunity to work 

with you again on any additional future testing projects. 

Sincerely, 

l ~ 

Phaneendra Uppalapati 

Air Qual' Engineer 

v 

Robert J. Lisy, 

Quality Assurance Officer 
Compliance Stack Emission Test Report Glen-Gerv Corporation Mid Atlantic Plant 

Table of Contents 

Page 

1.0 INTRODUCTION 2 

1.1 Summary of Test Program 2 

1.2 Key Personnel 2 

2.0 SUMMARY AND DISCUSSION OF TEST RESULTS 3 

2.1 Objectives and Test Matrix 3 

2.2 Field Test Changes and Problems 4 

2.3 Presentation of Results 4 

3.0 PLANT AND SAMPLING LOCATION DESCRIPTIONS 10 

3.1 Process Description and Operation 10 

3.2 Control Equipment Description 10 

3.3 Flue Gas Sampling Locations 10 

3.4 Process Sampling Location 11 

4.0 SAMPLING AND ANALYTICAL PROCEDURES 18 

4.1 Test Methods 18 

4.2 Procedures for Obtaining Process Data 19 

5.0 INTERNAL QA/QC ACTIVITIES 22 

5.1 QA Audits 22 

5.2 QA/QC Problems 22 

6.0 APPENDIX 27 

Test Date: October 10 and 11, 2007 Page 1 Air Compliance Testing, Inc. - 071008 
Compliance Stack Emission Test Report Glen-Gerv Corporation Mid Atlantic Plant 

1.0 INTRODUCTION 

1.1 Summary of Test Program 

Glen-Gery Corporation Mid Atlantic Plant, located in Shoemakersville, Pennsylvania contracted Air 

Compliance Testing, Inc. of Cleveland, Ohio to conduct compliance stack emission testing for their Bickley 

Kiln (Source ID: 102) and Harrop Kiln (Source ID: 101). Testing was performed to satisfy the emission 

testing requirements pursuant to Operating Permit No. 06-05065B. The testing was performed on October 

10 and 11, 2007. 

Simultaneous sampling was performed at the Bickley Kiln Dry Limestone Adsorber (DLA) Inlet Duct and 

at the Biekley Kiln DLA Exhaust Stack to determine the mass emission rate of hydrochloric aeid (HCI) and 

liydrofluoric acid (HF). Sampling was also performed at the Bickley Kiln DLA Exhaust Stack to determine 

the mass emission rate of total filterable particulate matter (PM). Testing was conducted while operating at 

a maximum production level for the products listed in the appendix. During this test, emissions from the 

Bicldey Kiln was controlled by a DLA. 

Simultaneous sampling was performed at the Harrop Kiln DLA Inlet Duct and at the Harrop Kiln DLA 

Exhaust Stack to determine the mass emission rate of HCI and HF. Sampling was also perforined at the 

Harrop DLA Exhaust Stack to determine the mass emission rate of total filterable PM. Testing was 

conducted while operating at a maximum production level for the products listed in the appendix. During 

this test, emissions from Harrop Kiln were controlled by a DLA. 

Visible Emissions (VEs) measured as percent opacity were also monitored at the Bickley Kiln DLA 

Exhaust Stack and at the Harrop Kihi DLA Exhaust Stack to determine the maximum six-minute average of 

opacity. 

The test methods that were conducted during this test were EPA Methods 1, 2, 3, 4, 5, 9, and 26A. 

1.2 Key Personnel 

The key personne) who coordinated this test program (and their phone numbers) were: 

Jerry Carrier, Director of Research/Development, Glen-Gery Corporation, 610-374-4011 

Roger Fitterling, Air Quality Program, Pennsylvania Dept of Environmental Protection, 610-916-0100 

Philip J. Billick, President, Air Compliance Testing, Inc. 800-372-2471 

Sin I-Ioi Chiew, Project Manager, Air Compliance Testing, Inc. 800-372-2471 

Test Date: October 10 and 11, 2007 aage 2 Air Compliance Testing, Inc. - 071008 
Compliance Stack Emission Test Report Glen-Gerv Corporation Mid Atlantic Plant 

2.0 SUMMARY AND DISCUSSION OF TEST RESULTS 

2.1 Objectives and Test Matrix 

The purpose of this test was to determine the mass emission rate of HCI and I-TF at the Bickley Kiln DLA Inlet 

Duct, Bickley ICiln DLA Exhaust Stack, Harrop Kiln DLA Inlet Duct, and at the Harrop Kiln DLA Exhaust 

Stack and also determine the mass emission rate of total filterable PM at the Bickley Kiln DLA Exhaust Stack 

and at the Harrop Kiln DLA Exhaust Stack while operating at maximum production levels for the products 

listed in the Appendix at a predetermined limestone extraction setting. VEs (measured ae %-opacity) were 

also determined at the Bickley Kiln DLA Exhaust Stack and at the Harrop Kiln DLA Exhaust Stack while 

operating at maximum production levels for the products listed in the Appendix at a predetermined limestone 

extraction setting. Testing was performed to satisfy the emission testing requirements pursuant to Operating 

Permit No. 06-05065B. 

The specific test ob,jectives for this test were to: 

Measure the concentration of HCI and HF at the Bickley Kiln DLA Inlet Duct and at the Bickley Kiln DLA 

Exhaust Stack and also measure the concentration of total tilterable PM at the Biekley Kiln DLA Exhaust 

Stack while operating at a maximum production level for the products listed in the Appendix at a 

predetermined limestone extraction setting. 

Measure the dry standard and actual volumetric flow rate of the stack gas at the Bickley Kiln DLA Inlet Duct 

and at the Bickley Kiln DLA Exhaust Stack while operating at a maximum production level for the products 

listed in the Appendix at a predetermined limestone extraction setting. 

Utilize the above variables to determine the mass emission rate of HCl and HF at the Bickley Kiln DLA Inlet 

Duct and at the Bickley ICiln DLA Exhaust Stack and also determine the mass emission rate of total 

filterable PM at the Bickley Kiln DLA Exhaust Stack while operating at a maximum production level for the 

products listed in the Appendix at a predetermined limestone extraction setCing. 

Measure the concentration of HCI and HF at the Harrop Kiln DLA Inlet Duct and at the Harrop Kiln DLA 

Exhaust Stack and also measure the concentration of total filterable PM at the Harrop Kiln DLA Exhaust 

Stack while operating at a maximum production level for the products listed in the Appendix at a 

predetermined limestone extraction setting. 

Measure the diy standard and actual volumetric flow rate of the stack gas at the Harrop Kiln DLA Inlet Duct, 

and at the Harrop Kiln DLA Exhaust Stack while operating at a maximum production level for the products 

listed in the Appendix at a predetennined limestone extraction setting. 

Utilize the above variables to determine the mass emission rate of HCl and HF at the Harrop Kiln DLA Inlet 

Duct and at the Harrop Kiln DLA Exhaust Stack and also detennine the mass emission rate of total filterable 

PM at the Harrop Kiln DLA Exhaust Stack while operating at a maximum production level for the products 

listed in the Appendix at a predetermined limestone extraction setting. 

Test Date: October 10 and 11, 2007 Page 3 Air Compliance Testing, Inc. - 071008 
Compliance Stack Emission Test Report Glen-Gerv Corporation Mid Atlantic Plant 

Determine the maxiinum six-minute average of opacity at the Bickley Kiln DLA Exhaust Stack and at the 

Harrop Kiln DLA Exhaust Stack while operating at maximum production levels for the products listed in the 

Appendix at a predetermined limestone extraetion setting. 

Table 2.1 presents the sampling and analytical matrix log for this test. 

2.2 Field Test Changes and Problems 

No field test changes or problems occurred during the performance of this test that would bias the accuracy of 

the results of this test. 

2.3 Presentation of Resu/ts 

A single sampling train was utilized during each run at each location to determine the mass emission rate of 

HCl and HF at the Bickley Kiln DLA Inlet Duct, Bickley Kiln DLA Exhaust Stack, Harrop Kiln DLA Inlet 

Duet, and at the Harrop Kiln DLA Exhaust Stack and also deterrnine the mass emission rate of total filterable 

PM at the Bickley Kihi DLA Exhaust Stack and at the Harrop Kiln DLA Exhaust Stack while operating at 

maximum production levels for the products listed in the Appendix at a predetermined limestone extraction 

setting. These sampling trains measured the stack gas volumetric flow rate, dry molecular weight, moisture 

content, and concentrations of HCI, HF, and total filterable PM. 

Table 2.2.1 displays the mass emission rate of HCI and HF measured at the Bickley Kiln DLA Inlet Duct and 

the mass emission rate of I-ICI, HF, and total filterable PM measured at the Bickley Kiln DLA Exhaust Stack 

while operating at a maximum production level for the products listed in the Appendix at a predetermined 

limestone extraction setting. 

Table 2.2.1 also displays the maxiinum 6-minute average of opacity measured at the Bickley Kiln DLA 

Exhaust Stack while operating at a maximum production level for the products listed in the Appendix at a 

predetermined limestone extraction setting. 

As displayed in Table 2.2.1, the HCI emissions from Bickley Kiln were measured to be slightly higher at the 

DLA outlet than at the DLA inlet. (Note that this phenomenon also occurred during prior DLA testing, 

including the testing completed at the Marseilles Plant during the November 2006 test event at P001.) At 

the time of this report, the reason for this occurrence is unknown but may simply be attributed to the inherent 

errors of the sampling methods and/or the potential presence of non-target compounds in the gas streams that 

may have produced HCI upon disassociation at elevated stack gas temperatures. As with previous instances, 

Air Compliance Testing, Inc. perforined a review of the sampling equipment, field data recorded during the 

test runs, and analytical laboratory data to verify the HCI results. After a thorough review of the available 

data, it is the opinion of Air Complacence Testing, Inc. that the HCI results displayed in Table 2.2.1 are 

reported correctly. Note that all HCl levels were well below permitted limits. 

Test Date: October 10 and 11, 2007 Page 4 Air Compliance Testing, Inc. - 071008 
Compliance Stack Emission Test Report Glen-Gerv Corporation Mid Atlantic Plant 

Table 2.2.2 displays the mass emission rate of HCI and HF measured at the Harrop Kiln DLA Inlet Duct and 

the mass emission rate of HCI, HF, and total filterable PM measured at the Harrop Kiln DLA Exhaust Stack 

while operating at a maxiinum produetion level for the products listed in the Appendix at a predetermined 

limestone extraction setting. 

Table 2.2.2 also displays the maximum 6-minute average of opacity measured at the Harrop Kiln DLA 

Exhaust Stack while operating at a maximum production level for the products listed in the Appendix at a 

predetermined limestone extraction setting. 

Test Date: October 10 and 11, 2007 Page 5 Air Compliance Testing, Inc. - 071008 
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Compliance Stack Emission Test Report Glen-Gerv Corporation Mid Atlantic Plant 

3.0 PLANT AND SAMPLING LOCATION DESCRIPTIONS 

3.1 Process Description and Operation 

The Glen-Geiy Mid-Atlantic Facility operates two natural gas-fired tunnel kilns. The kilns produce brick of 

various sizes and colors. Each kiln is equipped with identical dry limestone absorber (DLA) systems 

manufactured by Hellmich to control Hydrogen Fluoride and Hydrogen Chloride emissions. The Bickley Kiln 

and Harrop Kiln were in operation during the performance of this test. 

Figures 3.1.1 and 3.1.2 depict the process schematics. 

3.2 Control Equipment Description 

During this test, emissions from the Bickley Kiln and Harrop Kiln were each controlled by individual DLAs 

and the bypass damper for each DLA was closed during this test event. 

Bach DLA system is comprised of a single limestone cascade absorber equipped with a limestone silo atop the 

DLA, and an extraction system to provide crushed limestone to the cascade absorber tower. Exhaust gases 

from the kilns are passed through each absorber perpendicular to the crushed limestone that is slowly extracted 

from the base of the absorbers. Each limestone cascade absorber tower is equipped with a peeling drum at the 

base which mechanically removes the reacted outer layer of the crushed limestone. The "peeled" limestone is 

pneumatically conveyed from the peeling drum back to the limestone feed bins for re-use. The reacted layer 

that has been "peeled" from the limestone is discharged via gravity to hoppers for disposal. Both DLAs utilize 

the same grade of limestone obtained from the same source. A block flow diagram depicting one of the two 

kilns and DLA arrangements is attached. Althougli both kilns are not identical, the general eqaipment 

arrangements are identical for both kiln systems. 

3.3 Flue Gas Sampling Locations 

3.3.1 Bieklev Kiln DLA Inlet Duct 

The Bickley Kiln DLA Inlet Duct was elliptical in shape with ineasured inner diameters of 49.5-inches and 

49.9-inches. The duct was oriented in the horizontal plane and was accessed from a temporary scaffolding 

arrangeinent. Two (2) 3.5-inch I.D. sampling ports were located 90 1apart from one another at a location that 

met EPA Method l, Section 11.1.1 criteria. On April 25, 2007 the duct was traversed to verify the absence of 

cyclonic flow. An average yaw angle of 7.75° was measured. Therefore, the sampling location also met EPA 

Method 1, Section 11.4.2 criteria. During emissions sampling, the duct was traversed for stack gas volumetric 

flow rate, dry molecular weight, moisture content, and HCI and HF concentration determination. 

Test Date: October 10 and 11, 2007 Page 10 Air Compliance Testing, Inc. - 071008 
Compliance Stack Emission Test Report Glen-Gerv Corporation Mid Atlantic Plant 

3.3 2 Bickley Kiln DLA Exhaust Stack 

The BicMey Kiln DLA Exhaust Stack was elliptical in shape with measured inner diameters of 47.1-inches 

and 47.0-inches. The stack was oriented in the vertical plane and was accessed from a permanent platform. 

Two (2) 3.7-inch I.D. sampling ports were located 90° apart from one another at a location that met EPA 

Method 1, Section 11.1.1 criteria. On April 25, 2007 the stack was traversed to verify the absence of cyclonic 

flow. An average yaw angle of 4.75° was ineasured. Therefore, the sampling location also met EPA Method 

1, Section 11.4.2 criteria. During emissions sampling, the stack was traversed for stack gas volumetric flow 

rate, dry molecular weight, moisture content, and total filterable PM, HCI, and HF concentration 

determination. 

3.3.3 Harrop Kiln DLA Inlet Duct 

The Harrop Kiln DLA Inlet Duct was elliptical in shape with measured inner diameters of 48.5-inches and 

50.2-inches. The duct was oriented in the horizontal plane and was accessed from ground. Two (2) 3.5-inch 

LD, sampling ports were located 90° apart from one another at a location that met EPA Method 1, Section 

1 1.1.1 criteria. On April 26, 2007 the duct was traveraed to verify the absence of cyclonic flow. An average 

yaw angle of 6.13° was measured. Therefore, the sampling location also met EPA Method 1, Section 11.4.2 

criteria. During emissions sampling, the duct was traversed for stack gas volumetric flow rate, dry molecular 

weight, moisture content, and HCI and HF concentration determination. 

3 3.4 Harrop Kiln DLA Exhaust Stack 

The Harrop Kiln DLA Exhaust Stack was elliptical in shape with measured inner diameters of 47.1-inclies and 

47.2-inches. The stack was oriented in the vertical plane and was accessed from a permanent platform. Two 

(2) 3.8-inch I.D. sampling ports were located 90° apart from one another at a location that met EPA Method 1, 

Section 11.1.1 criteria. On April 26, 2007 the stack was traversed to verify the absence of cyclonic flow. An 

average yaw angle of 2.42° was measured. Therefore, the sampling location also met EPA Method 1, Section 

11.4.2 criteria. During emissions sampling, the stack was traversed for stack gas volumetric flow rate, dry 

molecular weight, moisture content, and total filterable PM, HCI, and HF concentration determination. 

Figures 3.2.1 - 3.2.4 schematically illustrate the traverse point and sample port locations utilized. 

3.4 Process Sampling Location 

Process sampling was completed by Glen-Gery as part of their QA/QC program and included raw material 

sampling at the pug mill as well as Fire Check ICey testing in the kiln. In addition, '/z brick was removed froin 

cars after the drier/prior to kiln entry as well as at kiln exit for purposes of mass balance testing if results of 

the stack test did not indicate compliance. Results from the QA/QC testing were unavailable at the time of 

this report. 

Test Date: October 10 and 11, 2007 Page 11 Air Compliance Testing, Inc. - 071008 
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Compliance Stack Emission Test Report Glen-Gerv Corporation Mid Atlantic Plant 

(2) 3.5" 

. Sampiing Ports 

Located 90° 

Apart 

. . 122.6" l 211.0" 

 2.44 Equivalent 

~ 

4.23 Equivalent 

Diameters Downstream -~ Diameters Upstream ~ 

From Disturbance From Disturbance 

' 49.5" x 49.9" I. D. 

-._.. 

Elliptical Stack 

-~ O _ 

Distance From Distance From 

Point 

% of Duct Depth Inside WaII (in.) Inside Wall (in.) 

Port1 Port 2 

1 2.1 1.0 1.0 ~. 

2 6.7 3.3 3.$ 

3 11.8 5.8 5.9 

4 17.7 8.8 8.8 

5 25.0 12.4 12.5 

6 35.6 17.6 17.8 

7 64.4 31.9 32.1 

8 75.0 37.1 37.4 

9 82.3 40.7 41.1 

10 88.2 437 44.0 

11 93.3 46.2 46.6 

12 ~ 97.9 48.5 48.9 

Figure 3.2.1 - Bickley Kiln DLA Inlet Duct Traverse Point Location Drawing 

Test Date: October 10 and 11, 2007 Page 14 Air Compliance Testing, Inc. - 071008 
Port 1 

r

-47.1" LD.--------- I 

6 

0 

h 

a 

ComDliance Stack Emission Test Report Glen-Gerv Corporation Mid Atlantic Plant 

m 

110.0" 

2.34 Equivalent Diameters 

Upstream from 

Disturbance 

(2) 3.7" I.D. 

~--- Sampling Ports 

Located 90°Apart 

Port 2 

663.0" 

14.08 Equivalent 

Diameters Downstream 

from Disturbance 

~_47.1" x 47.0" I. D. 

Elliptical Stack 

Distance From Distance From 

Point % of Duct Depth Inside Wall (in.) Inside Wall (in.) 

Port 1 Port 2 

1 4.4 2.1 2.1 

2 14.6 6.9 6.9 

3 29.6 119 13.9 

4 70.4 33.2 33.1 

5 85.4 40.2 40.1 

6 95.6 45.0 44.9 

Figure 3.2.2 - Bickley Kiln DLA Exhaust Stack Traverse Point Location Drawing 

Test Date: October 10 and 11, 2007 Page 15 Air Compliance Testing, Inc. - 071008 
Port 2 

Mnil 

I ~ 48.5" LD.-~ 

Compliance Stack Emission Test Report Glen-Gerv Corporation Mid Atlantic Plant 

126.0" 

~ 2.51 Equivalent 

Diameters Downstream 

From Disturbance 

48.5" x 50.2" LD. 

Eliipticai Stack 

(2) 3.5" 

Sampling Ports 

Located 90° 

Apart 

186.0" 

~ 

3.71 Equivalent 

Diameters upstream ~ 

From Disturbance 

~ 

Distance From Distance From 

inside WaII (in.) Inside Wall (in.) 

Point % of Duct Depth Port 1 Port 2 

1 2.1 1.0 1.1 

2 6.7 3.2 3.4 

3 11.8 5.7 5.9 

4 17.7 8.6 8.9 

5 25.0 12.1 12.6 

6 35.6 17.3 17.9 

7 64.4 31.2 32.3 

8 75.0 36.4 37.7 

9 823 39.9` 41.3 

10 88.2 42.8 44.3 

11 

-_ 

933 45.3 46.8 

12 97.9 . . . . . 47.5 ...49.1 ..... 

Figure 3.2.3 - Harrop Kiln DLA Inlet Duct Traverse Point Location Drawing 

Test Date: October 10 and 11, 2007 Page 16 Air Compliance Testing, Inc. - 071008 
~47.1" LD. j 

Port 1 

Port 2 

Distance From Distance From 

Point % of Duct Depth Inside Wall (in.) Inside Wall (in.) 

Port 1 Port 2 

Compliance Stack Emission Test Report Glen-Gerv Corporation Mid Atlantic Plant 

96.0" 

2.03 Equivalent Diameters 

Upstream from 

Disturbance 

(2) 3.8" LD. 

Q - ~ Sampling Ports 

Located 90°Apart 

660" 

13.98 Equivalent 

Diameters Downstream 

from Disturbance 

I 

_47.1 " x 47.2" I. D. 

Elliptical Stack 

1 4.4 21 2.1 

2 14.6 6.9 6.9 

3 29.6 13.9 14.0 

4 70.4 33.2 33.2 

5 85.4 40.2 40.3 

6 95.6 45.0 45,1 

Figure 3.2.4 - Harrop Kiln DLA Exhaust Stack Traverse Point Location Drawing 

Test Date: October 10 and 11, 2007 Page 17 Air Compliance Testing, Inc. - 071008 
Compliance Stack Emission Test Repo t Glen-Gerv Corporation Mid Atlantic Plant 

4.0 SAMPLING AND ANALYTICAL PROCEDURES 

4.1 Test Methods 

4.1.1 EPA Method 1: Sainple and Velocity Traverses for Stationary Source 

Principle: To aid in the representative measurement of pollutant emissions and/or total volumetric flow rate 

from a stationary source, a measurement site where the effluent stream is flowing in a known direction is 

selected, and the cross-section of the stack is divided into a number of equal areas. A traverse point is then 

located within each of these equal areas. This method was utilized in its entirety as per the proeedures 

outlined in 40 CFR Part 60, Appendix A. 

4.1.2 EPA Method 2: Determination of Stack Gas Velocity and Volumetric Flow Rate (Type S) 

Principle: The average gas velocity in a stack is determined from the gas density and from measurement of 

the average velocity head with a Type S(Stausscheibe or reverse type) pitot tube. This method was utilized in 

its entirety as per the procedures outlined in 40 CFR Part 60, Appendix A. 

4.1.3 EPA Method 3: Gas Analysis for the Determination of Dry Molecular Weight 

Principle: A gas sample is extracted from a stack by one of the following methods: (1) single-point, grab 

sampling; (2) single-point, integrated sampling; or (3) inulti-point, integrated sainpling. The gas sample is 

analyzed for percent CO Z , percent 02, and if necessary, for percent CO. For dry molecular weight 

determination a Fyrite analyzer will be used for the analysis. This method was utilized in its entirety as per 

the procedures outlined in 40 CFR Part 60, Appendix A. 

4.1.4 EPA Method 4: Determination of Moisture Content in Stack Gases 

Principle: A gas sample is extracted at a constant rate from the source; moisture is removed from the sample 

stream and determined either volumetrically or gravimetrically. This method was utilized in its entirety as per 

the procedures outlined in 40 CFR Part 60, Appendix A. 

4.1.5 EPA Method 5: Determination of Particulate Emissions frorn Stationary Sources (Filterable PM only) 

Principle: Particulate matter (PM) is withdrawn isokinetically from the source and collected on a glass fiber 

filter maintained at a temperature in the range of 120 t 14°C (248 t 25°F) or such other temperature as 

specified by an applicable subpart of the standards or approved by the Administrator, U.S. Environmental 

Protection Agency, for a particular application. The PM mass, which includes any material that condenses at 

or above the filtration temperature, is determined gravimetrically after removal of uncombined water. This 

method was utilized in its entirety as per the procedures outlined in 40 CFR Part 60, Appendix A. 

4.1.6 EPA Method 9: Visual Determination of the Opacity of Emissions from Stationary Sources 

Principle: The opacity of emissions from stationary sources is deterinined visually by a qualified observer. 

This method was utilized in its entirety as per the procedures outlined in 40 CFR Part 60, Appendix A. 

Test Date: October 10 and 11, 2007 Page 18 Air Compliance Testing, Inc. - 071008 
Compliance Stack Emission Test Report Glen-Gerv Corporation Mid Atlantic Plant 

4.1.7 EPA Method 26A: Determination of Hydrogen Halide and Halogen Emissions from Stationary SourcesIsokinetic Method 

Principle: This method is applicable for detennining emissions of hydrogen halides (HX) [hydrogen chloride 

(HCI), hydrogen bromide (HBr), and hydrogen fluoride (HF)] and halogens (X2) [chlorine (C12) and bromine 

(BrZ )] from stationary sources. This method collects the emission sample isokinetically and is therefore 

particularly suited for sampling at sources, sucli as those controlled by wet scrubbers, emitting acid particulate 

matter (e.g., hydrogen halides dissolved in water droplets). This method was utilized in its entirety as per the 

procedures outlined in 40 CFR Part 60, Appendix A. 

The sampling trains utilized during this testing project are depicted in Figures 4.1 and 4.2. 

4.2 Procedures for Obtaining Process Data 

Process data was recorded by Glen-Gery Corporation Mid Atlantic Plant personnel utilizing their typical 

record keeping procedures. Recorded process data was provided to Air Compliance Testing, Inc. personnel at 

the conclusion of this test event. The process data is located in the Appendix and included the following. 

Glen-Gery personnel recorded the following process data during the performance test: 

ICiln Tl7roughput (Tons fired brick/hour) 

Type of Brick in Kiln during testing 

Bypass Damper Position 

Limestone extraction setting 

Source and Grade of Limestone 

Test Date: October 10 and 11, 2007 Page 19 Air Compliance Testing, Ine. - 071008 
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Compliance Stack Emission Test Report Glen-GerV Corporation Mid Atlantic Plant 

5.0 INTERNAL C,tA/QC ACTIVITIES 

5.1 QA Audits 

Tables 5.1.1 - 5.3 illustrate the QA audit activities that were performed during this test. 

All meter boxes and sampling trains used during sainpling performed within the requirements of their 

respective methods as is shown in Tables 5.1.1 - 5.2. All pre-test and post-test leak checks were well below 

the applicable limit. Minimum metered volumes and percent isokinetics were also met where applicable. 

Table 5.3 displays the results of the EPA Method 26A Audit Sample analysis. The results were transmitted by 

e-mail to Mr. Bryon Richwine, Pennsylvania Dept of Environmental Protection. On November 6, 2007, Mr. 

Richwine infonned Air Compliance Testing, Ine. that the two (2) reported audit concentrations met EPA 

Method 26A, Section 11.5.3 criteria. 

Shawn Bodnar was certified on October 3, 2007 as a Visible Emissions Evaluator. The certification expires in 

six months from the issue date. 

For quality assurance, the observer obtained a view of the emissions with the best available contrasting 

background and with the sun oriented in the 140 °sector to his back. Readings were taken every 15 seconds 

and made to the nearest 5% opacity. 

5.2 QA/QC ProBlems 

No QA/QC problems occurred during this test event. 

Test Date: October 10 and 11, 2007 Page 22 Air Compliance Testing, Inc. - 071008 
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Compliance Stack Emission Test Report Glen-Gerv Corporation Mid Atlantic Plant 

6.0 APPENDIX 

Appendix attached. 

Test Date: October 10 and 11, 2007 Page 27 Air Compliance Testing, Inc. - 071008 
APPENDIX 

to 

Compliance Stack Emission Test Report 

Determination of Total Filterable Particulate 

Matter, Hydrochloric Acid, Hydrofluoric 

Acid and Visible Emissions 

Bickley Kiln (Source ID: 102) and Harrop Kiln 

(Source ID: 101) 

EPA Methods 1, 2, 3, 4, 5, 9, and 26A 

Glen-Gerv Corporation Mid Atlantie Plant 

Shoemakersville, Penosylvania 

Date Conducted: October 10 and 11, 2007 

Job Number: 071008 

Prepared by: 

Air Compliance Testing, Inc. 

PO Box 41156 

Cleveland OH 44141-0156 

Phone:(800) EPA-AIR1 (372-2471) 

Report Date: November 7, 2007 


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