ENTEC Services 

Pollution Control System Evaluation and Source El•issions Testing 

Cherokee Brick and Tile 

Compliance Emissions Re-Testing 

No. 1 and No. 2Kilns Dry lime Absorber Stack 

February 28, 2007 

Entec Project No.: 27125 

16-D Commerce Avenue Hueytown, Alabama 35023 Phone: (205) 491-6676 Fax (205) 491-6614 

www. entecservices, com 
Entec Services, Inc. 

16-D Commerce Avenue 

Hueytown, Alabama 35023 

Telephone: (205) 491-6676 

Fax: (205) 491-6614 

Results of the February 28, 2007 

Emissions Re-Testing for Particulate w/HCI / HF on 

No. 1 and Nn• _• Kilns Dry Lime Absorber St•ck •t the 

Cherokee Brick Facility located in 

Macon, Georgia 

Submitted to: 

Cherokee Brick and Tile Co. 

3250 Waterville Road 

Macon, Georgia 31206 

Attention: Mr. Jim Owens 

Entec Project No. 27125 

Completed By: 

Report Submitted" March 6, 2007 

Reviewed By: 

G •/, 

Tommy Lotz•Jr. 

Project Manager. 

Tom L•z• '• 

Technical Services Manager 

hereby certify to the best of my knowledge all field sampling and laboratory analysis performed 

for this report is authentic and accurate. It has been checked for completeness and accuracy. 
Cherokee Brick and Tile Co. 

Table of Contents 

.Section Pa_ae No. 

Executive Summary 

Emissions Summary 

Detailed Test Results 

Sampling Procedures 

Location of Test Ports 

Method 5/26A Sampling Train 

No.1 No. 2 Kilns Dry Lime Absorber Field Data Sheets 

Test Run 1 

Test Run 2 

Test Run 3 

Control Room Data 

Quality Control / Quality Assurance Procedures 

QA/QC Checklist 

Orifice Check and Temperature Check 

Fyrite / Orsat Standardization 

Laboratory Analysis 

Equipment Calibrations 

Nomenclature and Test Calculations 

3 

7 

11 

12 

13 

14 

17 

20 

23 

25 

30 

31 

32 

37 

54 

64 
Executive Summary 

Cherokee Brick located in Macon, Georgia, retained Entec Services, inc. to perform 

emissions re-testing on the No. 1 and No. 2 Kilns Dry Lime Absorber Stack. Mr. 

Tommy Lotz, Jr., and Mr. Jason English, of Entec Services, Inc. conducted the testing 

on February 28, 2007. Representing Cherokee .Brick was Mr. Jim Owens who 

coordinated testing with the control room production activity. Representing the state 

from the Georgia Department of Natural Resources was Mr. Daniel McCain. 

Entec Services, Inc. encountered no difficulties in the field collection of the samples or 

in the laboratory analysis of the samples 

The emissions test summary on the following page gives a detailed summary of each 

test run compared to the maximum emission limits set forth by the Georgia Department 

of Natural Resources. Test results indicate the emissions results were below the 

emissions standards set forth by Permit No. 3251-021-0167-V-02-0 ID No. PCD01, 

except for the Hydrogen Fluoride emissions in Ibslton of Fired Brick. 

Detailed Test 
SOURCE OWNER: 

PLANT LOCATION: 

SOURCE(S) NAME(S): 

SOURCE(S) CONDITION: 

SOURCE(S) SHAPE: 

Entec_.Services, Inc. 

SOURCE OVERVIEW 

Cherokee Brick and Tile 

Macon, GA 

Dry Lime Absorber Stack 

Compliance Testing (New Feed Rate) 

Circular 

PROBE WASH CHEMICAL: 

SOURCE PERMIT NUMBER: 

TEST PERFORMED: 

REFERENCE METHOD TESTS: 

PROJECT MANAGER 

ENVIRONMENTAL ANALYST PROJECT LEADER 

ENVIRONMENTAL ANALYST ASSISTANT 

OWNER'S REPRESENTATIVE: 

RULING AGENCY: 

RULING AGENCY REPRESENTATIVE: 

DATES TESTS CONDUCTED: 

ENTEC PROJECT NUMBER: 

Acetone 

3251-021-0167-V-02-0 ID No. PCD01 

Lime MACT Subpart JJJJJ 

Sample Location EPA Method 

Volumetric Flow EPA Method 

Molecular Weight EPA Method 

Moisture Content EPA Method 

Particulate EPA Method 

Hydrogen Chloride EPA Method 

Hydrogen Fluoride EPA Method 

Mr. Tommy Lotz Jr. 

Mr. Tommy Lotz Jr. 

Mr. Jason English 

Mr. Jim Owens 

Georgia Department of Natural Resources 

Mr. Daniel McCain 

02/28/07 

27125 

1 

2 

3 

4 

5 

26A 

26A 
ENTEC Services, Inc. 

16-D Commerce Ave. Hueytown, Alabama 35023 

INPUT TEST DATA 

Client: 

Source: 

Cherokee Brick and Tile 

Dry Lime Absorber Stack 

Field Data 

Run Number 

Test Date 

Time Test Run Began Ended 

,•=,,,•,,,,,• T;m• 

Stack Area 

Barometric Pressure 

Stack Static Pressure 

Pitot Tube Correction factor 

Meter Correction Factor 

Meter Delta H @ 

Nozzle Diameter 

Meter Volume 

Meter Temperature 

Avg. Orifice Delta H 

Impingers Weight Gain (Moisture) 

Silica Gel Impinger Weight Gain (Moisture) 

Oxygen Concentration, dry basis 

Carbon Dioxide Concentration, dry basis 

Avg. Sq. Rt. of Delta P 

Stack Temperature 

Total Hydrogen Chloride collected, mg 

Total Hydrogen Fluoride collected, mg 

]'otal particulate collected 

Symbol 

P• 

Cp 

Y 

Units 

Military Time 

minutes 

Ft 

in. Hg 

in. H20 

in. Hz0 

Job No.: 

Data Input By: 

02/28/07 

0845-0948 

22.166 

29.75 

0.15 

0.84 

1.004 

1.800 

27125 

T. Lotz, Jr. 

Test Data 

2 3 

02/28/07 02/28/07 

1107-1217 1254-1356 

22.166 

60 6O 

22.166 

29.75 30.02 

0.13 

0.84 

1.004 

1.800 

0.13 

0.84 

1.004 

1.800 

AVERAGE 

29.84 

0.14 

0.84 

1.004 

1.800 

Dn inches 0.312 0.312 0.312 0.312 

Vm dcf 45.677 45.924 45.373 45.658 

tm °F 69.8 87.8 

1.80 

115.0 

10.6 

in. H20 

grams 

grams 

(in. H20) 

F 

AH 

Wimp 

W=• 

O2 

COz 

(sqrt &P)avg 

91.9 83.2 

1.75 1.71 1.75 

108.6 111.5 111.7 

13.3 

16.0 

3.0 

0.557 

356.0 

HCL 27.5 

HF 

mn 

mg 

mg 

mg 

16.0 

80.0 

7.6 

16.0 

4.0 

0.550 

357.7 

27.6 

85.5 

58.8 

5.0 

0.566 

358.8 

69.9 

10.5 

16.0 

4.0 

0.558 

357.5 

27.5 

82.3 

59.1 

27.5 

81.4 

48.5 

5 
ENTEC Services, Inc. 

16-D Commerce Ave. Hueytown, Alabama 35023 

CALCULATED TEST DATA 

Client: Cherokee Brick and Tile 

Source: Dry Lime Absorber Stack 

Description Formulas 

Run Number 

Test Date 

Time Began-Ended 

1. Stack Pressure P• Pal 13.| 

2. Meter Pressure P•,• Nrl 113.• 

3. Standard Meter Volume 17.•4" Y* (V,dT=)* (P•,• +/•H 113.6] 

4a. Standard Volume of Water Vapor Condensed =0,04706=W• 

5. Moisture Fraction 

9. Molecular Weight Of Slack Gas, dry basis 

10. Molecular Weight Of Stack Gas, wet basis 

=(V•.q=,=• V,,,•l)l(V•¢l=• V•,,•.•) 

0.32"(O.z}+ 0.44"(CO= )+0.28"( 100-(O•)-(COz)] 

M=='('I -B,•)+ 18.0*(B•= 

11. Average Stack Gas Velocity 

12. Stack Gas Flow (• Stack Conditions 

85.49"Cp*(sqrt -•P)z,•'SQRT((T,) (P,'M,)} 

13. Stack Gas Flow @ Standard Conditions Q,'(T=•=rr,)'(P=/P=•} 

14. Stack Gas Flow @ Dry Standard Conditions 

14b. Hydrogen Chloride concentration @ Std.Cond.,Grains/Cu.Ft. 

14b. Hydrogen Fluoride concentration @ Std.Cond.,Grains/Cu.Ft. 

:15. Particulate concentration @ Standard Conditions 

15b. Hydrogen Chlodde emissions, Ibs per hour 

15b. Hydrogen Fluodde emissions, los per hour 

21. Particulate emissions 

22. Volume collected through nozzle 

24. Isokinetic Sampling Rate, Percent 

=(0.01543"HCL•)IQ• 

=(0.01543"HF,•)/Q.• 

=0.01543"m•/•dl 

=(60/7000)*HCLQ•*Q=t,• 

=(60/7000)'HFQ•*Q=t,• 

(60/7000)*c,*Q• 

:T=/P=*[0.002669"V•¢+ Vm*Y*Pm/'rm 

lO0*Vn (60*v,'A•*O) 

Post Meter Orifice Cal. (EMC ALT-O09 Yqa) 

% Difference, (Calibration must be within 5% of original Y-factor) 

Job No.: 27125 

Data Input BY: T. Lotz, Jr. 

Symbol Units Calculated Data 

2 3 AVERAGE 

02/28107 02/28107 02/28/07 

Military Time 0845-0948 1107-1217 1254-1356 

P, in. Hg 29.76 29.76 30.03 29.85 

p. in. Hg 29.88 29.88 30.15 29.97 

v,,,• dscf 45.626 44.359 43.891 44.625 

v,,•,,• sol 5.412 5.111 5.247 5.257 

;',,•,,.• • 0.•.•'00 0.627 0.358 0.495 

B•= fraction 0.1147 0.1145 0.1133 0.1142 

I• g/g-moin 29.440 29.120 29.280 29.280 

• g•g-moin 28.128 27.846 28.003 27.992 

v, rds 40.21 39.69 38.97 39.622 

Q, acfm 53,474 52,783 51,831 52,696 

Q, scfrn 34,284 33,957 33,578 33,940 

Q.• dscfm 30,352 30,067 29,776 30,065 

HCLcs gr/dscf 0.009 0.010 0.010 0.010 

HFcs grldscf 0.028 0.028 0.030 0.028 

cs grldscf 0.0164 0.0243 0.0207 0.0205 

HC! 4bs/hr IbsJhr 2.42 2.47 2.48 2.45 

HF -Ibs/hr Ibsrnr 7.16 7.17 7.67 7.33 

PMR Iblhr 4.27 6.27 5.28 5.27 

V. acf 80.387 77.873 76.405 78.222 

% 104.60 102.66 102.57 103.28 

0.9816 0.9827 0.9793 0.9812 

2.27% 
Sampling 
Procedures 

The particulate and gas emission rates were determined using EPA Methods 1-5, and 

26A, CFR Title 40, Part 60, Appendix A. The calibration and quality assurance 

procedures of EPA CFR 40 Part 60 Appendix A for all methods, and the "Quality 

Assurance Handbook for Air Pollution Measurement System" Volume III Stationary 

Source-Specific Methods were followed throughout the duration of the field and 

laboratory testing. 

The most current revision revised as of July 1, 2004, of each method (as described in 

the Federal Register) was used. 

Stack Gas Volumetric Flow 

The velocity of the gas stream was determined according to EPA Reference Method 1 

and 2 by reading the instantaneous velocity head with an inclined manometer at each 

sampling point with a calibrated S-type pitot tube attached adjacent to the sample 

nozzle. The stack pressure was measured with the static side of an S-type pitot tube. 

A calibrated pyrometer was used to measure stack temperature at each sampling point. 

Stack Gas Molecular Weight 

The carbon dioxide and oxygen concentrations were determined using EPA Reference 

Method 3 (Fyrite Method). A sample of the flue gas was extracted from the gas stream 

during each test. These samples were analyzed with a Fyrite gas analyzer. The 

molecular weight of the gas was calculated using the moisture, oxygen and carbon 

dioxide content and the measured stack gas temperature. 

Moisture Content 

The moisture content used for calculating the gas stream flow rate was determined by 

measuring the amount of condensed moisture in the glass impinger and silica gel 

impinger in the sampling train as described in EPA Reference Method 4 at the 

completion of each test. 

The moisture collection system consists of a series of 4 impingers connected to a silica 

gel impinger attached to the outlet. Ice is placed around the impingers to maintain a 
temperature <680 F. The outlet temperature of the impinger is monitored and recorded 

throughout the duration of the testing to verify the temperature is below <680 F. 

Hvdroqen Chloride I Fluoride with Particulate 

Preliminary data was used to determine stack temperature, pressure, and range of 

velocity heads, moisture content and stack gas dry molecular weight prior to sampling. 

The meter box was leak checked from the pump to the orifice. Initial and final leak 

checks of the sampling system and pitot lines were performed as outlined in Method 5 

and were recorded on the data sheets. The nozzle (glass with an angle of taper of 30 

degrees and of button hook design) was calibrated before and after the test using a 

micrometer and was also recorded on the field data sheets. 

The sampling probe was placed at each sampling point to provide a total sampling time 

of at least 60 minutes and a volume of at least 31.8 cubic feet. The gases were drawn 

through a glass nozzle attached to a heated glass lined probe. The probe was maintained at the proper setting to obtain a temperature of > 248 0 F. The gases then 

proceeded through borosilicate glass filter holder, with a Teflon frit filter support through 

a tarred Teflon or quartz fiber filter to remove particulate matter. The exit of the filter 

was maintained at a temperature of > 248 0 F. These temperatures were recorded at 

each point on the field data sheets. 

The gases were then scrubbed through a series of four impingers to capture hydrogen 

halides, and moisture. The optional moisture knockout impinger was not used in the 

sample train. The first and second impingers contained approximately 100 ml of a 0o 1N 

H2SO4 solution and the third and fourth impingers contained approximately 100 ml of a 

0.1 N NaOH solution. The fifth impinger contained pre weighed silica gel to remove any 

remaining moisture. The gases passed through the impinger series in an ice bath to 

maintain a maximum exit temperature of 68 0 F. This temperature will be also recorded 

on the field data sheets. The clean and cool gases then entered the meter box where 

the gas flow and temperature were measured. 

After the completion of each test run leak rate determinations were made and recorded 

on the field data sheets. Then the sampling train and the probe nozzle assembly were 
transferred to the cleanup area making sure no particulate was lost. The cleanup data 

was also recorded on the field data sheets and / or the laboratory checklist sheet. 

Particulate catches were placed in sealed petri dishes. Each acetone rinse from the 

nozzle, probe, and filter holder were combined and placed in a sealed container. The 

first, and second impinger contents were transferred to its tarred container, weighed 

and the rinsing from the glassware will be added to this container. The third and fourth 

impinger contents were weighed for moisture determination calculations but were not 

kept for analysis. The silica gel from the fifth impinger was transferred to its respective 

•,•u •u•,,•,• ahd w•,g•eu. For Lhe group of LesLs an acetone biank, suifuric acid 

solution, distilled water and. acetone of approximately 200 milliliters were placed in a 

sealed container. These containers will be clearly marked and transported to the 

laboratory for analysis. 

Enthalpy will perform all of the laboratory analysis and is an approved Louisiana 

accredited lab (Certification Number 04010) that meets all requirements for the State of 

Georgia approved and accredited laboratory. 

10 
Entec Services, Inc 

16 D Commerce Ave. Hueytown, AL 35023 

STACK DRAWING & TRAVERSE POINT LOCATION 

Client: Cherokee Brick and Tile Job No. 27125 

Source: Dry Lime Absorber Stack Input By: Jason English 

Type of Traverse: Velocity (V) or Particulate (P): 

Stack Diameter, inches: 63.75 

Stack Height, feet: 100 

P Port Type Flange Port Diameter 6.0" 

Stack Area, Ft2: 22.166 

Number of Ports: 2 

Stack Properties: Inches Duct Diameters 

Upstream Disturbance: 170.0 

Downstream Disturbance: 684.0 

2.67 

10.73 

Length of Port, inches: 

Total Number of Traverse Points: 

Number of Points per diameter: 

8.25 

12 

6 

63.8 INCHES 

170.0 NCHES 

Point No. 

Inside Stack Outside Nipple 

Inches Inches 

2.8 11•1 

2 9.3 17.6 

3 18.9 27.1 

4 44.9 53.1 

5 54.4 62.7 

6 60.9 69.2 

684.0 NCHES 

Adjusted pointe diameter > 24" no point closer than 1.0 inch 

Adjusted points diameter < 24" no point closer than 0.5 inch 

Stack Diameters between 12-24 inches minimum points are 8 

4 points per port if the 81 2 diameters downstream and 

upstream criteria is met. 
Method 5/26A Sampling Train 

Filter Exit Temperature 

(>248 F) 

48 F) 

•rature 

Sensors 

Impinger Exit Temperature 

(<68 F) 

nplng 

#3 

O.1N 

qaOI 

Ice Bath 

Exhaust oooo • ol 

Temp. and Flow 

Controllers 

Temperature 

Manometer 

[Pressure[ FDry Gas Meter 

12 
Field Data Sheets 

No. 1 & No. 2 Kilns Dry Lime Absorber Stack 

13 
Run No. 1 

Field Data Sheets 
ENTEC Services, Inc. 

16-D Commerce Ave. Hueytown, Alabama 35023 

Client: Cherokee'Brick and Tile Test Date: 2/2812007 

Source: Dry Lime Absorber Stack Run Number: 1 

PARTICULATE Wl HYDROGEN CHLORIDE HYDROGEN FLOURIDE FIELD DATA, EPA METHOD 5126A 

Traverse Point 

1-1 

1-2 

1-3 

1-4 

1-5 

2-1 

2-2 

2-3 

2-4 

2-5 

0.41 2.29 357 60 

0.42 0.6481 2.34 357 63 

0.35 0.5916 1.95 359 66 

0.32 0.5657 1.79 362 67 

0.29 0.5385 1.62 360 69 

1.80 

0.19 0.4359 1.06 

0.34 0.5831 1.90 

0.31 0.5568 1.73 

0.33 0.5745 1.84 

0.35 0.5916 1.95 

0.27 0.5196 1.51 

356 70 

360 69 

358 71 

358 73 

359 75 

360 76 

360 79 

358.8 

2-6 0.30 0.5477 1.67 

K-Factor 

5.58 0.32 0.5661 69.8 

15 
!!! 
Run No. 2 

Field Data Sheets 
ENTEC Services, Inc. 

16-D Commerce Ave. Hue_ytown, Alabama 35023 

Client: Cherokee Brick and Tile Test Date: 2/28/2007 

Source: Dry Lime Absorber Stack Run Number: 2 

PARTICULPARTICULATE Wl HYDROGEN CHLORIDE HYDROGEN FLOURIDE FIELD DATA, EPA METHOD 5126A 

1-1 0.34 

1-2 0.30 

1-3 0.33 

1-4 0.34 

1-5 

1-6 

2-1 

2-2 

2-3 

2-4 

2-5 

K-Factor 

0,29 

0.5831 

0.5477 

1.90 

1.67 

353 

355 

0.5745 1.84 357 86 

0.5831 1.90 357 87 

0.5385 1,62 360 88 

0.21 0.4583 

0,40 0.6325 

0.40 0.6325 

0.39 0.6245 

0.28 0.5292 

1.17 

2.23 

2.23 

2.18 

1.56 

0.5000 1.40 

0,4796 1.28 

0.5569 

0.25 

355 88 

352 88 

357 

358 

362 

356 

2-6 O.23 350 

5.58 

90 

91 

92 

90 

89 

1.75 356.0 87.8 

Run No. 3 

Field Data Sheets 
ENTEC Services, Inc. 

16-D Commerce Ave. Hueytown, Alabama 35023 

Client: Cherokee Brick and Tile Test Date: 2/2812007 

Source: Dry Lime Absorber Stack Run Number: 3 

PARTICULATE W/HYDROGEN CHLORIDE HYDROGEN FLOURIDE FIELD DATA, EPA METHOD 5126A 

T•verse Po.i.n.t _he!t_= p •q_ Rt De!f_• P nelt•_ H •P•el¢ T•np. (°F,• Meter T•m_rn• (°F) 

1-1 0.39 

1-2 0.40 

1-3 0.33 

1-4 0.27 

1-5 0.22 

1-6 0.20 

0.6245 2.18 354 92 

0.6325 2.23 358 88 

0.5745 1.84 358 89 

0.5196 1.51 359 91 

0.4690 1.23 358 91 

0.4472 1.12 356 91 

2-1 0.33 0.5745 1.84 354 91 

2-2 0.26 0.5099 1.45 359 93 

2-3 0.32 

2-4 0.29 

2-5 0.35 

2-6 0.31 

0.5657 1.79 360 93 

0.5385 1.62 359 94 

0.5916 1.95 359 94 

0.5568 1.73 358 96 

K-Factor 

5.58 0.31 0.5504 1.71 357.7 91.9 
o EE E 
Control Room Process Data 

 ̧23 
Production Data 

The following information was received by email from Mr. Jim Owens of Cherokee Brick 

And Tile Company for the testing performed at their, facility in Macon, Georgia, on 

FebruarY 28, 2007. 

The brick being fired were queen size in both kilns. 

The production data during the test for the emission rate was: 

Lingl Kiln No. 1 = 25 cars per day of Queen Size brick for a rate of 16.56 tons/hour 

Lingl Kiln No. 2 = 25 cars per day of Queen Size brick for a rate of 16.47 tons/hour 

The limestone usage was 175.5 pounds/hour. 

The average differential pressure was: 

06:00 am 9:00 am .79 

09:00 am 12:00 noon .80 

12:00 noon- 03:00 pm .77