r 

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Test Report 

Determination of Total Filterable Particulate 

Matter and Sulfur Dioxide Emissions 

Natural Gas Fired Tunnel Kiln No. 1(P002), 

Natural Gas Fired Brick Kiln No. 2(P008) and 

South Grinding Line (P901) 

EPA Methods l, 2, 3, 4, 5, and 6 

Glen Gery Corporation - Caledonia Plant 

Caledonia, Ohio 

Date Conducted: May 1-3, 2007 

Job Number: 061011 

Prepared by: 

14%/' COn1/JllaflC@ 

T@St% 1g, 117C. 

PO BoX 41156 

Cleveland OH 44141-0156 

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

Report Date: May 31, 2007 
Glen—Gery Corporation 

Technical Services / Research 

433 S Pottsville Pike 

Shoemakersville, PA 19555 

610/562-3076 

Fax:610-562-2084 

hftp://www.glengerybrick.com 

May 31, 2007 

OVERNIGHT DELIVERY 

Ohio Environmental Protiection Agency 

Northwest District Offiee 

Air Pollution Group 

347 N. Dunbridge Road 

Bowling Green, OH 43402 

Attn: Andrea Chapman 

Re: Titte V Stack Test Results 

Test Dates: May 1-3 2007 

Glen-Gery Corporation — Caledonia Plant 

Air Permit Facility ID# 03-51-00-0005 

Dear Ms, Chapman, 

As per the Intent to Test Notification sent March 29, 2007, testirng was completed on Tunnel Kiln 

No. I(P002) Tunnel Kiln No. 2(P008) and the South Grinding Line (P901). The results of the 

testing are enclosed with this letter. 

Although we had a few last minute issues with regarding acceptable testing procedures for the 

South Grinding Line, I wanted to thank you and Mr. Sattler for your assistance with regard to 

making the appropriate contacts and working out the proper operating parameters. I believe you 

will find we ran the test exactly as discussed. 

If you have any questions regarding this letter, please call me at (610) 562-3076. 

Again, I appreeiate all your help. 

Sincerely, 

Gle Gery C

~

ration 

Jerry Carrier 

Manager of Technical Services/Research 

ec: Tom Sattler, OEPA (without enclosure) 

Gerry Hatch, Glen-Gery Corporation 

File 
SuperiorQuality 

=7mTesting, 

Emission Testing. 

ValidResults 

Guaranteed. lr C~ 

P.O. Box 41156 Cleveland, Ohio 44141 

1-800-EPA-AIR9 www.aircomp.com 

testing@aircomp.com 

May 31, 2007 

Jerry Carrier 

EHS Manager 

Glen Gery Corporation - Caledonia Plant 

423 South Pottsville Pike 

Shoemakersville, Pennsylvania 19555 

Dear Jerry: 

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

May 1-3, 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 represent'ative within 30 days of the actual test 

day. 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. 

Sineerely, 

PV ~~~r✓i,~!!~~--'~ anelrndra Uppalapati 

Reporti Technic' n 

Robert J. Lisy, Jr. 

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

Table of Contents 

Page 

1.0 INTRODUCTION 2 

1.1 Summary of Test Progratn 2 

1.2 Key Personnel 2 

2.0 SUMMARY AND DISCUSSION OF TEST RESULTS 3 

2.1 Objeetives and Test Matrix 3 

2.2 Field Test Changes and Problems 3 

2.3 Presentation of Results 4 

3.0 PLANT AND SAMPLING LOCATION DESCRIPTIONS 9 

3.1 Proeess Deseription and Operation 9 

3.2 Control Equipment Description 10 

3.3 Flue Gas Sampling Locatioais ]0 

3.4 Process Sampling Location 10 

4.0 SAMPLING AND ANALYTICAL PROCEDURES 17 

4.1 Test Methods 17 

4.2 Procedures for Obtaining Process Data 18 

5.0 INTERNAL QA/QC ACTIVITIES 21 

5.1 QA Audits 21 

5.2 QA/QC Problems 21 

6.0 APPENDIX 25 

Production and Process Data 

Field Data Sheets 

Calibrations and Certifications 

Test Date: May 1-3, 2007 aage 1 Air Compliance Testing, Inc. - 061011 
Compliance Stack Emission Test Report Glen Gerv Corporation - Caledonia Plant 

'~ 1. ~';~1~~ ~ - •~~~. 

1.1 3ummary of Test Program 

Glen Gery Corporation - Caledonia Plant (Facility ID: 03-51-00-0005), located in Caledonia, Ohio 

contraeted Air Complianec Testing, Inc. of Cleveland, Ohio to conduct comptiance stack emission testing 

for their Natural Gas Fired Brick Kiln No. I(P002), Natural Gas Fired Tunnel Kiln No. 2(P008), and their 

South Grinding Line (P901). Testing was performed to satisfy the emission testing requirements pursuant 

to Glen-Gery Corporation's Ohio EPA Title V permit. The testing was perfonned on May 1-3, 2007. 

Sampling was performed at the P002 Exhaust Stack and at the P008 Exhaust Stack to determine the mass 

emission rate of sulfur dioxide (S0 2). Sampling was also performed at the P901 Baghouse Exhaust Stack to 

determine the mass emission rate total filterable particulate matter (PM). Testing was conducted during 

normal maximum achievable operations. During this test, emissions from P002 and P008 were uncontrolled 

and emissions from P901 were controlled by a baghouse. 

The South Grinding Line (P901) and Sand Applicator No. 1(P007) were both operating during the testing 

performed at the P901 Baghouse Exhaust Stack. P007 did not exhaust through the Dust Hog Dust Collector. 

Emissions from both P901 and P007 were exhausted through the SLY baghouse exhaust stack being tested 

(the P901 Baghouse Exhaust Stack). The Glen Gery Corporation - Caledonia Plant's North Grinding Line 

(P001) did not operate during this test event. 

The test methods that were conducted during this test were EPA Methods 1, 2, 3, 4, 5, and 6. 

1.2 Key Personnel 

The key personnel who coordinated this test prograin (and their phone numbers) were: 

Jerry Carrier, Glen-Gery Corporation, 610-562-3076 

Thomas Sattler, Ohio EPA, NWDO, 800-686-6930 

Wendy Ordway, Ohio EPA, NWDO, 800-686-6930 

Jay Liebrecht, Ohio EPA, NWDO, 800-686-6930 

Philip J. Billiek, President, Air Compliance Testing, Ine. 800-372-2471 

Sin Hoi Chiew, Project Manager, Air Compliance Testing, Ine. 800-372-2471 

Test Date: May 1-3, 2007 Page 2 Air Compliance Testing, Inc. - 061011 
Compliance Stack Emission Test Report Glen Gerv Corporation - Caledonia Plant 

2.0 SUMMARY AND DISCUSSION OF TEST RESULTS 

2.1 Objectives and Test Matrix 

The purpose of this test was to detennine the mass emission rate of S02 at the P002 Exhaust Stack and at the 

P008 Exhaust Stack and also to determine the mass emission rate tota) filterable PM at the P901 Baghouse 

Exhaust Stack during normal maximum achievable operations. Testing was performed to satisfy the emission 

testing requirements pursuant to Glen-Gery Corporation's Ohio EPA Title V permit. 

The speeifie test obiectives for this test were to: 

Measure the concentration of S0 2at the P002 Exhaust Stack and at the P008 Exhaust Stack and also to 

measure the concentration of total filterable PM at the P901 Baghouse Exhaust Stack during normal 

maximum achievable operations. 

Measure the dry standard and actual volumetric flow rate of the stack gas at the P002 Exhaust Stack, P008 

Exliaust Stack, and at the P901 Baghouse Exhaust Stack during normal maximum achievable operations. 

Utilize the above variables to determine the mass emission rate of S0 2at the P002 Exhaust Stack and at the 

P008 Exhaust Stack and also deterinine the mass emission rate of total filterable PM at the P901 Baghouse 

Exhaust Stack during normal maximum achievable operations. 

Tables 2.1.1 and 2.1.2 presents the sampling and analytica1 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. 

Test Date: May 1-3, 2007 Page 3 Air Compliance Testing, Inc. - 061011 
Compliance Stack Emission Test Report Glen Gerv Corporation - Caledonia Plant 

2.3 Presentation of Results 

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

SOzat the P002 Exhaust Stack and at the P008 Exhaust Stack during normal maximum achievable operations. 

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

and concentration of SOz . 

Table 2.2.1 displays the mass emission rate of S02 measured at the P002 Exhaust Stack and at the P008 

Exhaust Stack during normal maximum achievable operations. Note that the mass emission rates of S0 2 

measared at the P002 Exhaust Stack and at the P008 Exhaust Stack were both well below the Title V 

permitted liinit of 129.7 Ib/hr. 

A single sampling train was utilized during eaeh run to determine the mass em'rssion rate of total filterable PM 

at the P901 Baghouse Exhaust Stack during normal maximum achievable operations. These sampling trains 

measured the stack gas volumetric flow rate, dry molecular weight, moisture content, and concentration of 

total filterable PM. 

Table 2.2.2 displays the mass emission rate of total filterable PM at the P901 Baghouse Exhaust Stack 

during normal maximum achievable operations. Note that the mass emission rate of total filterable PM 

measured at the P901 Baghouse Exhaust Stack was well below the Title V permitted limit of 4.06 ]b/hr. 

The tota) filterable PM concentration values in Table 2.2.2 denoted with a'<' were measured to be below the 

minimum detection limit (MDL) of the applicable analytical method. Total filterable PM mass emission 

rates denoted with a'<' in Table 2.2.2 were calculated utilizing the applicable MDL concentration values 

instead of the "as measured" concentration values. The accepted MDL for EPA Method 5 is 0.0020 

grains/dscf for a 32 dscf sample. 

Test Date: May 1-3, 2007 Page 4 Air Compliance Testing, Inc. - 061011 
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Compliance Stack Emission Test Report Glen Gery Corporation - Caledonia Plant 

3.0 PLANT AND SAMPLING LOCATION DESCRIPTIONS 

3.1 Process ®escription and Operation 

The Glen-Gery Corporation - Caledonia, Ohio facility operates Natural Gas Fired Brick Kihi No. 1(P002), 

Natural Gas Fired Tunnel Kiln No. 2(P008), and South Grinding Line (P901). P002 and P008 each have a 

permitted rated capacity of 8.89 TPH. P901 has a permitted rated capacity of 25 TPFI. 

Title V Information: 

Emission Unit ID: #1 Kiln 

Emissions: 

Pollutant: Sulfur Dioxide 

Estiinated Maximum Emissions Rate: 129.7 Ib/hr 

Process Operations: 

Average Production: 16,700.00 lbs/hr 

Maximum Production: 17,787.00 Ibs/hr 

Maximum Annual Production: 77,907.00 tons/year 

Process Actual Annual Production: 73, 146.00 ton/year 

Process Flow; See Figure 3.1.1 

Emission Unit ID: #2 Kiln 

Emissions: 

Pollutant: Sulfur Dioxide 

Estimated Maximum Emissions Rate: 129.7 Ib/hr 

Process Operations: 

Average Production: 16,700.00 Ibs/hr 

Maximum Production: 17,787.00 Ibs/hr 

Maximum Annual Production: 77,907.00 tons/year 

Process Actual Annual Production: 73, 146.00 ton/year 

Process Flow: See Figure 3.1.2 

Emission Unit ID: South Grinding Line 

Emissions: 

Pollutant: Particulate Matter 

Estimated Maximum Einissions Rate: 4.06 lb/hr 

Process Operations: 

Average Production: 50,000 ]bs/hr 

Maximum Production: 50,000 Ibs/hr 

Maximum Amnual Production: 160,488.00 tons/yr 

Process Actual Annual Prodaction: 80,244.00 tons/yr 

Process Flow: See Figure 3.1.3 

Test Date: May 1-3, 2007 Page 9 AirCompliance Testing, Inc. - 061011 
Compliance Stack Emission Test Report Glen Gerv Corporation - Caledonia Plant 

3.2 Control Equipment Description 

During this test, emissions from P002 and P008 were uncontrolled and emissions from P901 were controlled 

by a baghouse. 

3.3 Flue Gas Sampling Locations 

3.3.1 P002 Exhaust Stack 

'I'he P002 Exhaust Stack was elliptical in shape with measured inner diameters of 29.9 inches and 30.0 

inches. The stack was oriented in the vert'rcal plane and was accessed from a permanent platform. Two (2) 

3.0-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. Prior to emissions sampling, the staek was traversed to verify the absence of cyclonic 

flow. An average yaw angle of 4.08° 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 S0 2 concentration determination. 

3.3.2 P008 Exhaust Stack 

The P008 Exhaust Stack was elliptical in shape with measured inner diameters of 29.9-inches and 30.1- 

inches. The stack was oriented in the vertical plane and was accessed froin a permanent platform. Two (2) 

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

Section 11.1.1 eriteria. Pr'ror to emissions sampling, the stack was traversed to verify the absence of cyclonic 

flow. An average yaw angle of 2.92° 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 cotrtent, and S0 2 concentratioddetermination. 

3.3.3 P901 Bap,house Exhaust Stack 

The P901 Baghouse Exhaust Stack had a measured inner diameter of 38.9-inches, was oriented in the vertical 

plane, and was accessed from a permanent platform. Two (2) 4.0-inch I.D. sampling ports were located 90° 

apart from one another at a location that inet EPA Method 1, Section 11.1.1 criteria. Prior to emissions 

sampling, the stack was traversed to verify the absence of cyclonic flow. An average yaw angle of 1.67 0was 

measured. Therefore, the sampling location also met EPA Method l, Section 1 1.4.2 criteria. During 

emissions sampling, the staek was traversed for stack gas volumetric flow rate, dry molecular weiglit, 

moisture content, and total filterable PM concentration determination. 

Pigures 3.2 - 3.5 sclieinatically illustrate the traverse point and sample port locations utilized. 

3.4 Process Sampling Location 

The EPA Reference Test Methods perfonned d'rd not specifically require that process samples were to be 

taken during the performance of this testing event. It is in the best krnowledge of Air Compliance Testing that 

no process samples were obtained and therefore no process sampling location was identified in this report. 

See Glen Gery Corporation - Caledonia Plant personnel for any process sampling locations which may have 

been utilized unknowingly to Air Compliance Testing, Inc. during this testing event. 

Test Date: May 1-3, 2007 Page 10 Air Compliance Testing, Inc. - 061 011 
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t Sampling Ports 

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Port 1 

n 

Compliance Stack Emission Test Report Glen Gerv Corporation - Caledonia Plant 

29.9" 

Port 2 

83.0" 

2.77 Equivalent 

Diameters Downstream 

from Disturbance 

_29.9" x 30.0" I.D. 

Elliptical Stack 

Distance From Distance From 

Inside Wall (in.) Inside Wall (in.) Point % of Duct Depth Port 1 Port 2 

1 2.1 1.0 1. 0 '. 

2 6.7 2.0 2.0 '. 

3 11.8 3.5 3.5 ' 

4 17.7 5.3 5.3 '. 

5 25.0 7.5 7.5 

6 35.6 10.6 10.7 

7 64.4 19.3 193 

8 75.0 22.4 22.5 

9 82.3 24.6 24.7 

10 88.2 . 26.4 26.5 

11 93.3 27.9 28.0 

12 97.9 28.9 29.0 

Fignre 3.2 - P002 Exhaust Stack Traverse Point Location Drawing 

Test Date: May 1-3, 2007 Page 14 Air Compliance Testing, Inc. - 061011 
Compliance Stack Emission Test Report Glen Gery Corporation - Caledonia Plant 

(2) 3,0" I.D. 

0 Sampling Ports 

Located 90OApart 

8 10 12 

7 9 11 

266.5" 

8.85 Equivalent Diameters 

Upstream from 

Disturbance 

Port 1 

79.0" 

2.62 Equivalent 

Diameters Downstream 

from Disturbance 

-

29.9" x 30. 1 " 1. D. 

Elliptical Stack 

Port 2 

Distance From Distance From 

Inside Wall (in.) Inside Wall (in.) 

Point % of Duct Depth Port 1 Port 2 

1 2.1 1.0 1.0 

2 6.7 2.0 2.0 

3 11.8 3.5 3.6 

4 17.7 5.3 53 

5 25.0 7.5 7.5 

6 35.6 10,6 10,7 

7 64.4 19.3 19.4 

75.0 22.4 22.6 

9 82.3 24.6 24.8 

88.2 26.4 26.5 

10 --:- 

933 27.9 28.1 

1 97,9 28.9 29.1 

Figure 3.3 - POOS Exhaust Stack Traverse Point Location Drawing 

Test Date: May 1-3, 2007 Page 15 Air Compliance Testing, Inc. - 061011 
Compliance Stack Emission Test Roort Glen GerV Corporation - Caledonia Plant 

38.9" 1. D. 

I Port 1 

23.0" 

0.59 Equivalent Diameters 

Upstream from 

Disturbance 

(2) 4.0" I.D. 

Sampling Ports 

Located 90OApart 

Port 2 

81.5" 

2.10 Equivalent 

Diameters Downstream 

from Disturbance 

~--38.9" I.D. Stack 

Point % of Duct Depth Distance From lnsirl. W.11 fi. i 

2.1 1.0 

2 6.7 2.6 

3 11.8 4.6 

4 17.7 6.9 ym 

5 25,0 9.7 

6 35.6 13.8 

7 64.4 25.1 

8 75,0 29.2 

9 82.3 32.0 

10 88,2 34.3 

11 93.3 36.3 

12 97.9 37.9 

Figure 3.4 - P901 Baghouse Exhaust Stack Traverse Po ➢ nt Location Drawing 

Test Date: May 1-3, 2007 Page 16 Air Compliance Testing, Inc. - 061011 
Compliance Stack Emission Test Report Glen Gerv Corporation - Caledonia Plant 

4.0 SAMPLING AND ANALYTICAL PROCEDURES 

4.9 Test Methods 

4.1.1 EPA Method l: Sample and Velocity Traverses for Stationary Source 

Principle: 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 

procedures 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 Pitot Tube) 

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(Stausseheibe or reverse type) pitot tube. This inethod 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 ofthe following methods: (1) sing1e-point, grab 

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

analyzed for percent CO2, percent 0 2, and if necessary, for percent CO. For dry molecular weight 

determination, either an Orsat or a Fyrite analyzer inay 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 

Prine'rple: 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 Metihod 5: Determination of Particulate Emissions from 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 ternperature in the range of 120 ± 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 Ageney, for a particular application. The PM mass, which ineludes any material that condenses at 

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

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

4.1.6 EPA Method 6: Determination of Sulfur Dioxide Emissions from Stationary Sources 

Principle: A gas sample is extracted from the sainpling point in the stack. The sulfuric acid mist (including 

sulfur trioxide) and the sulfur dioxide (SO z ) are separated. The S02 fraction is measured by the bariuwnthorin titration method. 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. 

Test Date: May 1-3, 2007 Page 17 Air Compliance Testing, Inc. - 061011 
Comtpliance Stack Emission Test Repo t Glen Gerv Corporation - Caledonia Plant 

4.2 Procedures for Obtaining Process Dafa 

Process data was recorded by Glen Gery Corporation - Caledonia 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. 

The total output ofthe South Grinding Line (P901) was determined as follows: 

' 9 cuts/minute x 22 brieks/cut = 198 brick/minute x 60 minutes = 11,880 

11,880 brick/hr x 3.8 Ibs/dry brick = 45,144 ]bs/hr 

45,144 ]bs/hr / 20001bs/Ton = 22.572 Tons per hr 

22.572 tph / 50 tph = 90.288 % of capacity 

Test Date: May 1-3, 2007 Page 18 Air Compliance Tesfing, Inc. - 061011 
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Compliance Stack Emission Test Report Gien Gerv Corporation - Caledonia Plant 

6.0 INTERNAL QAIQC ACTIVITIES 

5.1 QA Audits 

Tables 5.1 - 53 illustrate the QA audit activities that were performed during this test. 

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

respective inethods as is shown in Tables 5.1 and 52. 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. 

Tab1e 5.3 displays the results of the EPA Method 6 Audit Sample analysis. The results were transmitted by email to Mr. Jay Liebrecht, Environmental Specialist, Ohio EPA, NWDO. On May 29, 2007, Mr. Liebreeht 

informed Air Compliance Testing, Ine. that the results of the Audit Sample were acceptab1e. 

5.2 QA/QC Problems 

No QA/QC problems occurred during this test event. 

Test Date: May 1-3, 2007 Page 21 Air Compliance Testing, Inc. - 061011 
Compliance Stack Emission Test Report Glen Gerv Corporation - Caledonia Plant 

P002 Exhaust Stack 

Method 6 Sampling Train Run I Ran 2 Run 3 

Leak Rate Observed Pre/Post efm 0.003 / 0.001 0.003 / 0.001 0.002 / 0.000 

Applicable Method Allowable Leak Rate cfm <0.020 <0.020 <0.020 

Acce table Yes Yes Yes 

Volume of Dry Gas Collected dse 30.514 30.241 30.278 

Recommended Volume of Dry Gas Collected dsc 21.000 21.000 21.000 

Acee table Yes Yes Yes 

Percent of Isokinetic Sam lin Rate % 98.2 100.1 100.2 

Applicable Method Allowable Isokinetic Sam lin Rate % 100 t 10 100 ± 10 100 t 10 

Acce table Yes Yes Yes 

P008 Exhaast Stack 

Method 6 Sampling Train Run 1 Run 2 Run 3 

Leak Rate Observed Pre/Post cfm 0.002 / 0.000 0.002 / 0.000 0.001 / 0.000 

Applicable Method Allowable Leak Rate efm < 0.020 < 0.020 < 0.020 

Acce table Yes Yes Yes 

Volume of Dry Gas Collected dsc 36.161 36.325 36.547 

Recommended Volume of Dry Gas Collected dsc 21.000 21.000 21.000 

Acce table Yes Yes Yes 

Percent of Isokinetic Sampling Rate % 100.1 99.3 99.2 

Applicable Method Allowable Isokinetic Sampling Rate % 100 f]0 100 i 10 100 ± 10 

Acce table Yes Yes Yes 

P901 Baghouse Exhaust Stack 

Method 5 Sampling Train Run 1 Run 2 Run 3 

Leak Rate Obseived Pre/Post cfm 0.001 / 0.000 0.001 / 0.000 0.002 / 0.000 

Applicable Method Allowable L,eak Rate cfm < 0.020 < 0.020 < 0.020 

Acce table Yes Yes Yes 

Volume of D Gas Collected dso 40.788 39.113 40.649 

Recommended Volume of Dry Gas Collected dsc 21.000 21.000 21.000 

Acee table Yes Yes Yes 

Percent of Isokinetic Sampling Rate % 98.2 98.9 100.2 

Applicable Method Allowable Isokinetic Sainpling Rate % 100 t 10 1 o01 10 100 t 10 

Aece table Yes Yes Yes 

Table 5.1 - EPA Method 5 and 6 Sample Train Audit Results Table 

Test Date: May 1-3, 2007 Page 22 Air Compliance Testing, Inc. - 061011 
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Compliance Stack Emission Test Report Glen Gerv Corporation - Caledonia Plant 

1 ._. ••' - 1 f U 

Appendix attached. 

Test Date: May 1-3, 2007 Page 25 Air Compliance Tesfing, Inc. - 061011 
APPENDIX 

to 

Compliance Stack Emission Test Report 

Determination of Total Filterable 

Particulate Matter and Sulfur Dioxide 

Natural Gas Fired Tunnel Kiln No. 1(P002), 

Natural Gas Fired Brick Kiln No. 2(P008) and 

South Grinding Line (P901) 

EPA Methods 1, 2, 3, 4, 5, and 6 

Glen Gerp Corporation - Caledonia Plant 

Caledonia, Ohio 

Date Conducted: May 1-3, 2007 

Job Number: 061011 

Prepared by: 

Air Compliance Testing, Inc. 

PO Box 41156 

Cleveland OH 44141-0156 

Phone: (800) EPA-AIR7 (372-2471) 

Report Date: May 31, 2007 
Caledonia Plant 

Stack Test Data 

neakr 1 9 s qnm 

*Push 

Location Date Rate (Min) 

Pieces 

Per Car Weight 

Slack Test 

Throughput 

(Tons/Hour) 

Max. Capacity 

Tltle V(Tons/Hr) 

% of Max 

Capacity 

Product 

Type Size Color 

Kiln #1 5/1/2007 45 3,198 3.84 8.19 8.89 92.09 Extruded Modular Aberdeen 

32.00 cars per tla 

Kiln#2 51212007 45 3,198 3.84 8.19 8.89 92.09 Extruded Modular Aberdeen 

32.00 cars per day 

- ruso rcare is carninuous 

Grinding Room Bag House 

Production Brick Weight Max. Capadty % of Max 

Location Date Cuts/Min Brick/Cut Brick/Hr Weight Lb/Hr Tons/Hr TiOe V(TonsMr) Capacity 

P901 South 

Grintl Line 5/312007 9 22 11880 3.84 45619.2 22.8096 25 91.24