EPA 114 INFORMATION COLLECTION REQUEST

HCL, HF , PM, Cl2, METALS, DIOXIN/FURAN

EMISSIONS TESTING

AUGUSTA (AUGUSTA, GA) PLANT #4 & PLANT #5

EAST SPENCER (SALISBURY, NC) PLANT # 6

( 770 ) 645

- 4529 Mary Ann Keon, Environmental Director

Source Test i ng Conducted:

September 15 th

- 22 nd , 2010

ATC Project Number

P

- 10142

ANALYTICAL TESTING CONSULTANTS, INC.

1630 Dale Earnhardt Blvd.

Kannapolis, N. C. 28083

(704) 932

- 3193 telephone

(800) 733

- 3193 toll

- free

(704) 932

- 0570 facsimile

corp@atc

- net.net e

- mail

www.atc

- net.net Web site

Distribution:

Mr s

. Mary Ann Keon

( F ive copies )

Iss ue Date:

February 7 , 2011

Revised:

March 1, 2011 Certificate #04044 E xpiration Date 6/30/11 Accreditation Limited to LELAP ScopeBoral Bricks Inc

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### TABLE OF CONTENTS

Page No.

Introduction

................................ ................................ ................................ ................................ ...... 3

Certification of Results

................................ ................................ ................................ .................... 4

Source Description

................................ ................................ ................................ ........................... 5

Plant Operations Summary

................................ ................................ ................................ .............. 6

Emissions Summary

- Plant 4

................................ ................................ ................................ .......... 7

Emissions Summary

- Plant 5

................................ ................................ ................................ ........ 1 2

Emissions Summary

- Plant 6

................................ ................................ ................................ ........ 17

Sampling and Analytical Procedures

................................ ................................ ............................. 22

Refer ences

................................ ................................ ................................ ................................ ...... 31

Appendix

................................ ................................ ................................ ................................ ........ 32Boral Bricks Inc

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### INTRODUCTION

This report presents the results of filterable particulate matter (PM) , hydrogen chloride (HCl)

, hydrogen fluoride (HF)

, chlorine (Cl2), multiple metals (including Hg) and dioxin/furan (D/F)

emissions testing p erformed on the outlet of the dry lime injection fabric filter baghouse on Brick

Kiln # 4 , Brick Kiln #5 ( at Boral Bricks, Inc Augusta, Georgia facility) and Brick Kiln #6 (at

Boral Bricks, Inc. East Spencer, North Carolina facility)

. In addition, one (1) dryer was selected

from each plant and tested for D/F only.

The following table outlines the methodology utilized.

US EPA

Methodology Description Isokinetic

Sampling? Notes

1

- 2 Determination of Volumetric Flow

rates No S

- type pitot tube

3a

Inlet/Outlet Oxygen/Carbon dioxide concentration

determinations No Semi

- continuous

analyzers

4

Inlet/Outlet Determination of Stack Moisture

Content Yes Combined with USEPA

M5 outlet/26A inlet

5

Outlet Only Determination of TSP particulate Yes Three ( 3 ) 1

- hr runs

23 Determination of Polychlorinated

Dibenzo

- P

- Dioxins and

Polychlorinated Dibenzofurans Yes Three (3) 4

- hr runs

26a

Inlet/Outlet Determination of Hydrogen Halide and

Halogen Emissions from Stationary

Sources Yes Combined with M5 on

Outlet/M4 on Inlet

29 D etermination of Metals Emissions Yes Three (3) 1

- hr runs

Test ing was conducted by ANALYTICAL TESTING CONSULTANTS, INC., Kannapolis,

North Carolina. Members of the test team were Bill Kissel, James Roberts, Larry Kirkman Sr.,

Larry Kirkman Jr. , and Phill ip Sisk

.

Mary Ann Keon, David Johnson, Wayne Kolar and Kelly McCormick represented Boral Bricks

.Boral Bricks Inc

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### REPORT CERTIFICATIONS

CERTIFICATION OF RESULTS BY TEST FIRM

“ By our signature we certify that the testing and the reporting of the test results cont ained herein are

prepared to the best of our abilities and that, to our knowledge, the data have been calculated and reported

correctly. No data or information has knowingly been omitted.”



# Bill Kissel 1/26/11 Kent Childers 1/26/11

Report Author/Da te Report Review/Date

Bill Kissel J. Kent Childers

President Sr. Project Manager



### CERTIFICATION BY RESPONSIBLE PLANT OFFICIAL

“The undersigned certifies under penalty of law that all information and statements provided in

this repor t (including any attachments), based on information and belief formed after reasonable

inquiry, and are true, accurate and complete.”

Signature Date

Name (Printed or Typed) Title (Printed or Typed)Boral Bricks Inc

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### SOURCE DESCRIPTION

Testing was cond ucted at the outlet of the dry lime injection fabric filter (CE41) that controls

acid gas (HCl and HF) and particulate emissions released from the gas

- fired brick tunnel kiln s

. The control system utilizes inject ion of hydrated lime into the brick kiln exh aust stream which

reacts with HF and HCl to form calcium fluoride and calcium chloride. The spent lime (CaF and

CaCl) is removed from the exhaust air stream by bagfilters and is transported off site for

disposal. The baghouse exhaust gas contains un

- reac ted pollutants and particulate matter.

Testing was also conducted at the outlet of a dryer stack (some dryers have multiple stacks, one

representative stack was selected for each plant) associated with each plant. “Green” brick are set

on a kiln car and p laced in a holding area where initial drying occurs. From the warming area

, bricks enter the dryer where the temperature is raised and most of the process water is removed

before entering the kiln. In the kiln, final evaporation of the process water takes place as well as

oxidation, vitrification, and the cooling process. All heat used in this process is formed in the

kiln and waste heat is used for the dryer with no supplementary heat. After exiting the kiln,

bricks are packaged and stored on site for s ale.

The purpose of this test was to satisfy an EPA request for information.Boral Bricks Inc

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### PLANT OPERATIONS SUMMARY

Boral Bricks, Augusta Plant 4 Operating Conditions during Stack Test

September 15

- 16 , 2010

Provided by Boral Bricks Inc.

DATE THROUGHPUT

(TPH) LIME FEED

(LBS/HR)

9/15/10 6.75 17

9/16/10 4.82 17

Boral Bricks, Augusta Plant 5 Operating Conditions during Stack Test

September 17

- 18, 2010

Provided by Boral Bricks Inc.

DATE THROUGHPUT

(TPH) LIME FEED

(LBS/HR)

9/17/1 0 1 4. 65 142

9/18/10 1 4. 65 142

Boral Bricks, Salisbury Plant 6 Operating Conditions during Stack Test

September 21

- 22, 2010

Provided by Boral Bricks Inc.

DATE THROUGHPUT

(TPH) LIME FEED

(LBS/HR)

9/21/10 20.26 210

- 240

9/22/10 20.26 210

- 240Boral Bricks Inc

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### EMISSIONS SUMMARY

PLANT 4Boral Bricks Inc

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### EMISSIONS SUMMARY

PLANT 5Boral Bricks Inc

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### EMISSIONS SUMMARY

PLANT 6Boral Bricks Inc

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### SAMPLING AND ANALYTICAL PROCEDURES

Particulate Mat ter

Particulate Matter (PM) testing and analysis were performed according to procedures developed

by the U. S. Environmental Protection Agency (US EPA) and referred to as Method 5 . Method 5

sampling was performed in combination with the Method 26A procedu res . Sampling port

locations and number of test points to be used were determined according to Method 1.

ATC Laboratory Equipment for Gravimetric Analysis

Laboratory Technician Keith Poole utilized the following equipment in the analysis of US EPA

met hod five samples

.

1) Precisa 303A Analytical Lab Balance

- certification and annual

maintenance by Precision Weights, Inc. (completed 4 / 19 /20 1 0).

Prior to each use, the balance is calibrated with NIST Traceable weights

0.5000, 5 0 .0000, 10 0.0000, and 2 00.0000 grams, and

2) a Nalgene® 5317

- 0180 Dessicator cabinet with indicating desi c cant.

ATC’s laboratory environment is maintained at 68 + 10 o F and humidity levels maintained at less

than 50% with all samples stored in a controlled environment dessicato r with the same

temperature requirements cited above and humidity levels at 15 + 8% RH.

Prior to the field test, filter media were prepared by sequentially numbering Whatman® 934AH

3" quartz filters with a non

- bleeding marker and oven drying. Duplicate weights were then

performed on the filters to reach a constant weight. Additionally, sufficient quantities of

numbered 150ml Griffin beakers were thoroughly washed with warm, soapy water and oven

dried. Once cooled, the beakers were also weighed to a con stant weight and stored in the

dessicator cabinet until needed.

After field testing and recovery, each filter was stored individually in petri dishes until

transferred to the dessicator for a period of no less than twenty

- four hours at room temperature

an d constant relative humidity; filters were then weighed to a constant weight (to the nearest 0.1

mg

- weighings over minimum of six hour period).

A blank of the acetone reagent was collected in the field, along with the samples and analyzed

side by side. A n appropriate portion of acetone (density 0.788 mg/l) was evaporated. The

maximum allowable residue according to US EPA QA/QC documentation is 0.0001% grams.

The net gain of the acetone blank was applied based upon this and a ratio of the volume of the

s ample to the volume of the blank according to the following e quation

.Boral Bricks Inc

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F ilter blank s w ere processed in conjunction with the samples and are recorded in the gravimetric

lab report for QA/QC purposes only.Boral Bricks Inc

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- 10142) Page 24 of 32 Particulate Sampling Train Schematic (US EPA M5)Boral Bricks Inc

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HCl , HF, CL2 Sampling

HCl , HF, and CL2 testing and analysis were performed according to procedures

developed by the U. S. Environmental Protection Agency (US EPA) and referred to as

Method 26a and co mbined with US EPA Method 5 for compliance particulate

determinations

. The impinger contents are as represented in the sketch on the following

pages. The contents of the impingers in the all

- glass sampling train were 0.1 N H 2 SO 4 in

impingers one and two, 0.1 N NaOH in impingers three and four, and 300 grams of silica

gel in impinger five. Enthalpy Analytical of Durham, NC performed the HCl , HF, and

CL2 analyses. The back half of the sampling train (0.1 N NaOH) was analyzed for Cl 2

. Please refer to the lab report for additional details on the HCl , HF, and CL2 analysis.

Multiple Metal Sampling

Multiple metals determinations were conducted according to US EPA M ethod 29. The

impinger contents are as represented in the sketch on the following pages (inclu ding

knockout impinger). The nozzle, probe liner and filter holder were all either quartz glass

or pyrex. A 3" Pallflex 2500QATUUP quartz fiber filter was utilized to filter the

sampled air. The temperature of the incoming gas was maintained at 250 o F + /

- 25

through the probe and also at the exhaust of the filter. Please refer to the page preceding

the sketch of the sampling train for an explanation of sample fractions.

All metals train sample recovery was conducted on site. Sample fractions were pla ced in

appropriately sized glass amber jars with Teflon lids and sealed and labeled. Samples

were delivered to First Analytical Labs in Chapel Hill, NC for analysis.Boral Bricks Inc

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Container ID

from USEPA

method 29 Container

Descr iption Laboratory

Sample Fraction Special Notes

1 Sample Filter For Hg

- Fraction 1

For others

- Front Half

3 0.1 N HNO 3 rinse of front

half of train For Hg

- Fraction 2B

For others

- Front Half

4 Contents of impingers 1 &

2 (5% HNO 3 /10% H 2 O 2 )

and rinsate (0.1 N HNO 3 ) Non

- Hg analysis

Back Half Fraction

5a Contents of impinger 3

(initially empty) and rinsate

(0.1 N HNO 3 ) For Hg

- 3a

For others

- Back Half

Fraction

5b Contents of impingers 4 &

5 (4% KMnO 4 /10% H 2 SO 4 )

and rinsate w/ same Hg o nly

Fraction 3B

5c Rinsate of impingers 4 & 5

with 8N HCl Hg only

Fraction 3C

6 Silica Gel container 6 for moisture determination only

8A 0.1 N HNO 3 blank 8A

8B Water blank 8B

9 5% HNO 3 /10% H 2 O 2 blank 9

10 4% KMnO 4 /10% H 2 S O 4

blank 10

11 8N HCl blank 11

12 Quartz Filter blank 12Boral Bricks Inc

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Dioxin/Furan Sampling

Dioxin/Furan determinations were conducted according to US EPA Method 2 3 . The sampling

train is represented in the sketch below . The nozzle, probe liner and filter holder were all either

quartz glass or pyrex. A 3" filter (provided by the analytical laboratory) was utilized to filter the

sampled air. The temperature of the incoming gas was mainta ined at 250 o F +/

- 25 through the

probe and also at the exhaust of the filter.

All dioxin/furan train sample recovery was conducted on site. Sample fractions were placed in

appropriately sized glass amber jars with Teflon lids and sealed and labeled. Samples were

delivered to Alta Analytical Perspective s, Inc. in Wilmington, NC f or analysis.

USEPA Method 23 Sampling TrainBoral Bricks Inc

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### Quality Assura nce Procedures

The following steps were conducted to ensure the accuracy and precision of this test project.

1. All laboratory glassware was cleaned and prepped according to US EPA methodologies

and ATC SOPs prior to use.

2. All laboratory glassware used for gravimetric determinations were weighed in duplicate

with agreement required to within a difference of less than 0.0005 grams.

3. All sampling equipment (nozzles, pitot tubes, modules, exit gas thermometers,

thermocouple bridges, etc) has primary calibration s performed on an annual schedule.

4. All sampling equipment was visually inspected prior to assembly in the shop.

5. Sampling trains were leak checked at a vacuum of no less than 15” Hg prior to the start of

sampling.

6. At the conclusion of the sampling projec t, pitot tubes were inspected according to US

EPA method 2 specifications, thermocouples calibrated, and the sampling module

calibrated at test ranges.

7. All data that has been entered into an Excel spreadsheet in the field and on pre

- printed

ATC forms was double

- checked in the office and reviewed.

8. A draft report was generated and submitted for review.

9. The President (Mr. Bill Kissel ) r eviewed and signed this report prior to release.Boral Bricks Inc

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### REFERENCES

1. CODE OF FEDERAL REGULATIONS, Title 40 , Part 60, Appendix A, July 1, 2009.Boral Bricks Inc

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# APPENDIX