JUN - 5 2008 
Stationary Source Sampling Report 

Brick Kiln Exhaust 

Triangle Brick Company 

Meny Oaks, North Carolina 

Trigon Project No. 046-06-076 

August 2006 
STATIONARY SOURCE SAMPLING REPORT 

FOR 

TRIANGLE BRICK COMPANY 

MERRY OAKS, NORTH CAROLINA 

Brick Kilns 1 and 2 Exhausts 

Performed by: 

Trigon Engineering Consultants, Inc. 

6200 Harris Technology Boulevard 

Charlotte, North Carolina 28269 

704.598.1049 

Trigon Project No. 046-06-076 

August 2006 
Stationary Source Sampling. Triangle Brick Company 

Brick Kilns I and 2 Exhausts. Merry Oaks, North Carolina 

Seprember I, 2006 

Trigon Project No. 046-06-076 

REPORT CERTIFICATION 

This report, the testing details, and the final results have been performed under the supervision and reviewed 

by the persons named below. Results contained in this report relate only to the items tested. This report 

shaH not be reproduced in full or in part without the written consent of Trigon Engineering Consultants, 

1nc. 

Date oc;/os-Lo~ ; / Signature &r 1. )1-~ 

Bryan L. Starnes 

Project Manager 

Air Monitoring Department 

Trigon Engineering Consultants, Inc. 

Date 6 '1 (o5(t~6 Signature n.~{~ Lr 

W. Quentin Best 

Quality Assurance Manager 

Air Monitoring Department 

Trigon Engineering Consultants, Inc. 

Date ot/) /ov 

r t Signature ?cuJ !J.itl 

Paul R. Jenkins, Jr. 

Program Manager 

Air Monitoring Department 

Trigon Engineering Consultants, Inc. 

TRIGON ENGINEERING CONSULTANTS, INC LELAC CERTIFICATE No. 04036 Pnge 2 of 17 
Stationm)' Source Sawpling, Triangle Brick Company 

Brick Kilns I and 2 Exhausts, ;\-len)" Oaks. North Carolina 

TABLE OF CONTENTS 

Sep1ember I. 2006 

Trigon Project No. 046-06-076 

1.0 INTRODUCTION ....................................................................................................................... .4 

1.1 Purpose ............................................................................................................................... .4 

1.2 Outline of Test Program ..................................................................................................... .4 

1.3 Test Participants .................................................................................................................. 5 

2.0 PROCESS DESCRIPTION ......................................................................................................... 6 

2.1 Discussion ........................................................................................................................... 6 

3.0 SAMPLING METHODS ............................................................................................................. 8 

3 .I Sampling Strategy ............................................................................................................... 8 

3.2 Sampling and Analytical Procedures .................................................................................. 8 

3.3 Sampling Ports, Traverse Points and Cyclonic Flow Determination .................................. 8 

3.4 Stack Gas Velocity and Volumetric Flow Rate Determination .......................................... 8 

3.5 Dry Molecular Weight Determination ................................................................................ 9 

3.6 Moisture Determination .................................................................................................... I 0 

3.7 Particulate Matter, Hydrogen Chloride, and Hydrogen Fluoride Sampling ..................... !! 

3. 9 Sampling Ports and Points ................................................................................................. 12 

Figure 2 -Brick Kiln Nos. I & 2 Exhaust... .......................................................... 13 

3.6 Quality Assurance and Quality Control ............................................................................ 14 

4.0 RESULTS .................................................................................................................................... 16 

4.1 Summary of Results .......................................................................................................... 16 

4.2 Discussion ......................................................................................................................... 16 

5.0 APPENDICES ............................................................................................................................. 17 

Number of pages in Appendices - 7 5 

A. Summary of Results and Example Calculations 

B. Field Data Sheets 

C. Laboratory Data 

D. Production Data 

E. Calibration Data 

TRIGON ENGINEERING CONSULTANTS, INC. LELAC CERTIFICATE No. 04036 Page 3 of 17 
Stationary Source Sampling, Triangle Brick Company 

Brick Kilns I and 2 Exhausts, Merry Oaks, North Carolina 

1.0 INTRODUCTION 

September I. 2006 

Trigon Project No. 046-06-076 

This section describes the purpose, a brief outline including the sampling and analytical strategy, and the 

personnel involved in the test program. 

1.1 Purpose 

The purpose of this sampling project was to determine concentrations and emission rates of particulate 

matter, hydrogen chloride and hydrogen fluoride from the Brick Kilns I and 2 Common Scrubber located at 

the Triangle Brick Company facility in Merry Oaks, North Carolina. The results of the sampling and the 

documentation provided in this report will be used for compliance evaluation according to Air Permit 

Number 06897T08 issued by the North Carolina Departroent of Environment and Natural Resources 

(NCDENR). 

1.2 Outline of Test Program 

Stationary source sampling was performed on August 10,2006 by the Air Monitoring Department of Trigon 

Engineering Consultants, Inc. (Trigon). Three 1.5 hour sampling runs were conducted at the Kiln I and 2 

Common Scrubber Stack. The sampling runs were conducted during normal production and operating 

conditions. United States Environmental Protection Agency (US EPA) Methods I through 5 were used for 

the determination of particulate matter concentrations and emission rates. Method 26A was used for the 

determination of hydrogen chloride and hydrogen fluoride concentrations and emission rates. The specific 

application of these methods will be described in Section 3.0, Sampling Methods. The sampling and 

analytical procedures used in this test program were those established by the US EPA in standard reference 

test methods and appropriate sampling and analytical procedures. 

TRIGON ENGINEERING CONSULTANTS, INC. LELAC CERTIFICATE NO. 04036 Page 4 of 17 
StationmJ-' Source Sampling, Triangle Brick Company 

Brick Kilns I and 2 Exhausts, Merry.· Oaks, North Carolina 

1.3 Test Participants 

September/, 2006 

Trigon Project No. 0-16-06-076 

A list of the project participants, titles, affiliation and telephone numbers can be found below. 

Participant Title Affiliation Contact 

Telephone: 704.598. I 049 

Bryan L Starnes Project Manager Trigon Engineering Facsimile: 704.598.1050 

Consultants, Inc. E-mail: 

bstarnes@trigoneng.corn 

Larry (Chip) Reynolds Senior Environmental Trigon Engineering 

Scientist Consultants, Inc. 

Lenesto D. Page Environmental Trigon Engineering 

Scientist Consultants, Inc. 

Colby Engineering & Telephone: 860.491.9664 

William G. Colby President Consulting Facsimile: 860.491.2211 

E-mail : bcolby@opton1ine.net 

Vice President Triangle Brick 

Howard P. Brown, Jr. Production and Telephone: 919.624.9196 

Engineering Company 

TRiGON ENGINEERiNG CONSULTANTS. /NC. LELAC CERTIFICATE No. 04036 Page 5 of !7 
Statwnmy Source Sampling, Triangle Brick Company 

Bnck Kilns I and 2 Exhausts .. \Jerry Oaks . .Vorth Carolina 

2.0 PROCESS DESCRIPTION 

,September 1. 2006 

Trigon Project .\a. 046-1J6-0)6 

This section contains a brief description of the brick kiln, the control devices and an air flow schematic. 

2.1 Discussion 

Triangle Brick operates three natural gas fired kilns (Kiln Nos. I, 2, and 3) at its facility in Merry Oaks, 

North Carolina. Kiln Nos. I and 2 vented emissions through a common scrubber CD-KIK2 control device. 

A twenty-four car shuttle was conveyed through Kilns I and 2 yielding approximately 24.69 tons/hr of 

bricks fired for the August I 0, 2006 test. This production weight information was provided by Kathy 

Wheeler of Triangle Brick. The flue gases were withdrawn from the gas-fired tunnel(s) through a scrubber, 

!.D. fan, and stack to the atmosphere. Figure I details the air flow schematic. 

Production data was recorded by Triangle Brick personnel and is presented in Appendix D. 

TNH,I)N E: .. xa/\'1-'i-m\'1; ( 'oi\'SU/_ HNJ s. lAC LELAC C!:R fJFICAl'l- :\'() 0-1036 Page 6 of J 7 
Stationary Source Sampling, Triangle Brick Company 

Brick Kilns I a11d 2 Exhausts, Merry Oaks, Aorth Carolma 

Brick Kilns 1 and 2 System 

Atmosphere 

Stack 

t 

I J.D. Fan 

t 

CD-KJK2 Scrubber 

Kilns 1 and 2 

Figure 1 

Process Air Flow Schematic 

TRIGON ENGJN££RJNG CONSULTANTS, INC. LELAC CERTIFICATE No. 04036 

I 

September I, 2006 

Tr1gan Project ,Vo 046-06-076 

4,--Sampling Location 

Pagelafll 
Stationary Source Sampling, Triangle Brick Company 

Brick Kilns I and 2 Exhausts, ,\Jerry Oaks, North Carolina 

3.0 SAMPLING METHODS 

September I, 2006 

Trigon Project No. 046-06-076 

This section describes the sampling strategy, sampling and analytical methods, and quality assurance/quality 

control procedures implemented during this project. 

3.1 Sampling Strategy 

The sampling and analytical procedures used during this test program were those established by the US 

EPA. The sampling runs were conducted in triplicate to validate the sampling. Tests were conducted 

during normal operating conditions. 

3.2 Sampling and Analytical Procedures 

The US EPA methods used in this sampling program were Method I for the location of sampling ports and 

points, and determination of cyclonic flow, Method 2 for volumetric flow rate determination, Method 3 for 

the determination of dry molecular weight of the stack gas, Method 4 for the determination of moisture in 

the stack gas. Methods 5 and 26A were used for the determination of particulate, hydrogen chloride and 

hydrogen fluoride emissions. A sampling and analysis synopsis for these methods is discussed briefly in the 

following subsections. These test methods are available in the Code of Federal Regulations Volume 40, 

Part 60 or by request from Trigon. 

3.3 Sampling Ports, Traverse Points and Cyclonic Flow Determination 

The sampling location was prepared according to the criteria in Method 1. The duct diameters upstream and 

downstream from the sampling ports were determined prior to sampling. The number of traverse points was 

chosen with respect to sampling port location. For particulate traverses Method 1 specifies a minimum of 8 

traverse points for sampling ports located >8/>2 downstream/upstream stack diameters from flow 

disturbances and 24 traverse points when located >2/>0.5. The amount of cyclonic flow was determined 

according to the criteria detailed in Method I. 

3.4 Stack Gas Velocity and Volumetric Flow Rate Determination 

Method 2 is used for determining the average gas velocity in a stack from measurements of gas density and 

the average velocity head with a TypeS (Stausscheibe or reverse type) pi tot tube. This method is applicable 

for quantifYing gas flows which meet the criteria of Method I. In principle, measurements of velocity head 

and temperature are performed at the traverse points specified by Method I. A properly scaled differential 

TRIGON ENGINEERING CONSULTANTS, iNC. LELAC CERTIFICATE No. 04036 Page8of/7 
Stationary Source Sampling. Trinngle Brick Company 

Brick Kilns 1 and 2 Exhausts, Merry Oaks, North Carolina 

September 1, 2006 

Trigon Project No. 046-06-076 

pressure gauge was selected for the range of i.\p values encountered during the traverse. A 0 to I 0 inches of 

water inclined manometer was used as the differential pressure gauge. 

During this project, the sampling locations met the criteria detailed in Method I. Gas stream density was 

determined by Method 3. Moisture determination was performed by Method 4. The principal components 

of the gas velocity measurement system were sequentially: 

• A calibrated stainless steel TypeS pilot tube and Type K thermocouple; 

• Leak-free interface tubing between pi tot tube and differential pressure gauge; 

• A 0 to I 0 inch inclined manometer; and 

• An NIST traceable pyrometer. 

The apparatus was set-up according to manufacturer and reference method recommendations. Pre-test and 

post-test leak checks were conducted using procedures outlined in Method 2, Section 3.1. Velocity head and 

temperature measurements were performed at the traverse points specified by Method 1. The atmospheric 

and static pressure of the stack was also determined for the velocity head readings. The volumetric flow 

rate calculations used were those specified in Method 2, Section 5. A more comprehensive explanation of 

the reference method is detailed in the Quality Assurance Handbook for Air Pollution Measurement 

Systems: Volume Ill, EPA/600/R-94/038c, (QA Handbook) Field Procedure 2. 

3.5 Dry Molecular Weight Determination 

Method 3 is applicable for determining carbon dioxide and oxygen concentrations and dry molecular weight 

of a sample from a gas stream of a fossil-fuel combustion process. This method may also be applicable to 

other processes where it has been determined that compounds other than carbon dioxide, oxygen, carbon 

monoxide, and nitrogen are not present in concentrations sufficient to affect the results. 

In principle, a gas sample was withdrawn from the emission source by multi-point, integrated sampling. The 

collected sample was then analyzed for percent carbon dioxide, percent oxygen, and percent carbon 

monoxide. The dry molecular weight determination was performed by an Orsat analyzer. 

During this project, the gaseous components were collected using a Method 3 sampling system following 

the analytical procedures outlined in the reference method. The principal components of the sampling 

system were sequentially: 

TRIGON ENGINEERING CONSULTANTS, {NC. LELAC CERTTFICATE NO. 04036 Page 9 of 17 
Stationary Source Sampling, Triangle Brick Company 

Brick Kilns J and 2 Exhausls, Merry Oaks, Norlh Ct1rolina 

• A stainless steel probe; 

• A one-way squeeze bulb, to transport the sample to the Tedlar bag; 

• A saturator tube to remove particulate matter and excess moisture; and 

September I, 2006 

Trigon Projecl No. 046-06-076 

• A leak-free Tedlar bag equipped with a double-end shut-off quick connect. 

The analysis was performed with an Orsat type combustion gas analyzer within 8 hours of sample 

collection. The dry molecular weight was calculated using Equation 3-1, Section 7 of Method 3. The 

analyzer was maintained and operated according to the instructions recommended by the manufacturer and 

in accordance with Method 3 criteria. The analyzer was leak-checked according to Section 6 of Method 3. 

The oxygen reagent was validated by analyzing a sample of ambient air which must meet the specifications 

of 20.9% ± 0.3%. 

3.6 Moisture Determination 

Method 4 involves the determination of stack gas moisture. The moisture content is used to correct the 

emission concentration or mass emission rate to a dry basis. EPA Method 4 and Field Procedure 4 of the 

QA Handbook was used to measure stack gas moisture content. Field Procedure 4 provides detailed 

information on the application of Method 4. 

Preliminary flue gas moisture content (for purposes of setting the isokinetic flow rate) was determined using 

wet bulb/dry bulb thermometers and partial pressure, vapor and saturated vapor pressure equations. This 

technique is described in Method 4 and is summarized below: 

• Moisten the wet bulb thermometer wick with deionized water; 

• Insert both thermometers into the flue gas stream and monitor the wet bulb temperature; 

• When the wet bulb temperature has stabilized, record both the wet bulb and dry bulb 

thermometer temperatures; and 

• Calculate the flue gas moisture content (PMV) using the appropriate equations. 

The moisture content for emission rate calculations was determined in conjunction with the Method 5/26A 

isokinetic sampling train. The reference method involves the withdrawal of gaseous and particulate 

pollutants from the emission source at an isokinetic rate using a Method 5 sampling system. The sampling 

and analytical procedure for reference Method 4 will be discussed in detail in the following sections with 

the isok:inetic sampling procedures. 

TRiGON ENGINEERING CONSULTANTS, INC LELA C CERTIFICATE No. 04036 Page !Oof/7 
Srationmy Source Sampling, Triangle Brick Company 

Brick Kilns 1 and 2 Exhausts, Merry• Oaks, North Carolina 

Septenlber 1, 2006 

Trigon Project No. 046-06-076 

3.7 Particulate Matter, Hydrogen Chloride, and Hydrogen Fluoride Sampling 

Testing for particulate matter, hydrogen chloride, and hydrogen fluoride was performed according to 

Method 26A procedures. Gaseous and particulate pollutants were withdrawn isokinetically from the 

emission source and collected in a multi-component sampling train. In principle, particulate matter that was 

condensed at or above the filtration temperature of approximately 248 degrees Fahrenheit was collected on a 

tared quartz fiber filter. The gaseous components were then bubbled through a measured volume of O.IN 

sulfuric acid and 0.1N sodium hydroxide to determine the moisture, hydrogen chloride, and hydrogen 

fluoride content of the emission source. The principal components of the sampling system were 

sequentially: 

• A borosilicate glass sample nozzle and probe liner; 

• A heated (248°F ±25°F) probe and filter assembly with tared quartz fiber filter; 

• An impinger train consisting of five sequential impingers. Impingers one and two containing 

100 m1 each of an absorbing solution consisting of dilute sulfuric acid (0.1 N H2S04). 

Impingers three and four contained 100 m1 of dilute sodium hydroxide (O.lN NaOH) followed 

by a final impinger containing 200 grams of silica gel; and 

• A metering system capable of maintaining an isokinetic sampling rate and accurately 

determining the sample volume according to specifications in APTD-0581. 

Sample clean up began immediately after each test run. The filter, which collected the sample, was 

carefully removed from the Teflon filter support and sealed in a Petri dish. The nozzle, probe liner, and 

front filter-half of the filter assembly were rinsed with acetone into a glass storage container, which was 

sealed, and the liquid level marked. The sample containers were transported to Trigon's Air Quality 

Laboratory in Charlotte, North Carolina for particulate matter analysis. 

Hydrogen chloride and hydrogen fluoride were collected in the O.lN sulfuric acid solution in impingers one 

and two. The liquid in the first two impingers was measured to the nearest milliliter and recorded in order 

to determine the moisture content. 1be collected sample was placed in a high-density polyethylene (HOPE) 

storage container along with the deionized water rinse of impingers one, two, three and connecting 

glassware. The container was sealed and the liquid level was marked. 

The moisture collected by the silica gel in the sixth impinger was determined to the nearest 0.1 gram. 

Collected condensate measurements were recorded on the "moisture determination and sample recovery 

TRJGON ENGINEERING CONSULTANTS, INC. LELAC CERTIFiCATE No. 04036 Page 11 of 17 
Stationary Source Sampling, Triangle Brick Company 

Brick Kilns I and 2 Exhausts, Aferry Oaks, North Carolina 

September I, 2006 

Trigon Project No. 046-06-076 

data analysis" form. The samples were then shipped to Element One Laboratories of Wilmington, North 

Carolina with chain-of-custody documentation where they were analyzed by ion chromatography. Results 

of the hydrogen chloride and hydrogen fluoride analysis along with Element One's quality assurance data 

package can be found in Appendix C. 

The particulate matter analyses began by transferring the acetone samples to tared beakers. These samples 

were taken to dryness, and then placed in a desiccator along with the filters for an initial drying period of 24 

hours. The particulate mass was determined gravimetrically. The tare weights of the filters and beakers 

were subtracted from the final weights to determine the gross particulate weight. 

An aliquot of the reagent grade acetone was analyzed to determine the blank correction factor. The acetone 

rinse (corrected for the blank) was added to the filter catch to obtain the total particulate weight. The 

particulate samples and method blanks were analyzed by Trigon Engineering Consultants, Inc. personnel. 

The laboratory analyses and chain of custody documentation can be found in Appendix C. 

3.9 Sampling Ports and Points 

The dimensions of the stacks and the location of the sampling ports and points are detailed in Figure 2. 

Method I sampling criteria was maintained. The stack cross section for Kiln Nos. I and 2 was divided into 

12 equal areas. The ports for each stack were labeled A and B. During the test runs on Kiln Nos. I and 2, 

the traverse points were sampled for 7.5 minutes per point which yielded a total test time of90 minutes. 

TRJGON ENGINEERING CONSULTANTS, INC. LELAC CERTIFICATE No. 04036 Page 12oJI7 
Stationary Source Sampling. Triangle Brick Company 

Brick Kilns 1 and 2 Exhausts. Merry Oaks, Nortb Carolina 

Brick Kiln Nos. 1 and 2 Exhaust 

180" t 

i 

A B I 

0 A 

l SECTION 

K K 

>540" 

Not to Scale 

Figure 2 

Location of Sampling Ports and Points 

TRIGON ENGINEERING CONSULTANTS, INC LELACCERTIFICATE No. 04036 

September 1, 2006 

Trigon Project No. 046-06-076 

B 

63.25" 

K-K 

Page 13 ofl7 
Stationary Source Sampling, Triangle Brick Company 

Brick Kilns I and 2 Exhausts, Merry Oaks, North Carolina 

3.6 Quality Assurance and Quality Control 

September l, 2006 

Tngon Project No. 046-06-076 

Trigon has established quality assurance and quality control (QNQC) guidelines for providing quality 

sampling and analytical data from source tests. These QNQC procedures were implemented to ensure the 

acceptability and reliability of the data generated. 

In summary, an appropriate degree of data quality was maintained throughout this project. Leak checks and 

isokinetic QA criteria were met. The sampling trains were leak checked prior to and immediately after 

sampling. Leak rates for the isokinetic sampling trains were less than the maximum criterion of 0.02 cubic 

feet per minute. The sampling rates were also within the 100% ± 10% criterion. Quality control procedures 

for the particulate matter determinations have included the analysis of an acetone rinse blank, which must be 

less than 0.00 I% for the acetone residue. Spike and recoveries were performed for the sampling 

methodologies used. An analyte spike was added to a portion of a prepared sample and recovered to within 

70 and 130 percent of the known concentration. The results of the QA criteria for this project are 

summarized in the following tables and can be. Detailed results of the method blanks are reported in 

Appendix C with the laboratory data. 

Isokinetic Quality Control Actual Criteria 

Brick Kiln Nos. 1 and 2 Run2 Run3 Run4 

5/26A Train Post-Leak Check 0.002 0.003 0.003 < 0.020 cu. Ft. 

5/26A Train !so kinetics 98.6% 98.8% 100.9% 100± 10% 

Post-Test Meter Calibrations 

ALT-009 Meter Calibration (I± 0.05) Meter Box 300.390- Y ~ 1.03 

TRIGON ENGINEERING CONSULTANTS, INC. LELAC CERTIFICATE No. 04036 Page 14 of l7 
Stationary' Source Sampling. Triangle Brick Company 

Brick Kilns 1 and 2 Exlumsts. Merry Oaks. North Carolina 

Kiln Nos. 1 and 2 Common Scrubber 

Laboratory Quality Controls Actual 

Acetone Rinse Blank 0.00030% 

HCl Duplicate Analysis 

Kiln No.1 & 2 

RPD/RSD% 

Runl Run2 Run3 

26A 0.5% 0.8% 1.1% 

HCl Spike Recovery 

Percent Recovery Kiln No.1 & 2 

26A 98% 

HF Duplicate Analysis 

Kiln No.1 & 2 

RPDIRSD% 

Run 1 Run2 Run3 

26A 1.7% 0.5% 0.3% 

HF Spike Recovery 

Percent Recovery Kiln No.1 & 2 

26A 103% 

September 1. 2006 

Trigon Project /1/o. 046-06-076 

Criteria 

< 0.001% 

Criteria 

<10% 

Criteria 

100 ± 10% 

Criteria 

<10% 

Criteria 

100 ± 10% 

Field data and final laboratory results were entered into Trigon's Air Quality Data System by an 

environmental scientist, independently audited by the Project Manager, and reviewed by the Quality 

Assurance Manager for verification of data. After QC review by the QA Manager, the Technical Services 

Manager verified the final report for completeness and reasonableness of data. The report was returned to the 

Project Manager for review and preparation of the final draft. The report requires the signature of the Project 

Manager, Quality Assurance Manager, and the Program Manager before release to the client. Data and final 

reports are archived in a secured area for a minimum period often years. 

Trigon's field and laboratory test equipment has been maintained and calibrated in accordance with quality 

assurance procedures established by the US EPA in the QA Handbook. Equipment calibrations including 

pre-test and post-test calibration data are presented in Appendix E. 

TRIGON ENGINEERING CONSULTANTS, INC. LELAC CERTIF'ICATE No. 04036 Page 15 of 17 
Smtionary Source Sampling. Triangle Brick Company 

Brick Kilns 1 and 2 Exhnusts. Meny Oaks, North Carolina 

4.0 RESULTS 

September 1, 2006 

Trigon Project No. 046-06-076 

This section presents a summary of the particulate matter, hydrogen chloride, and hydrogen fluoride 

sampling. Detailed sampling results and example calculations for the test program can be found in 

Appendix A. Field data sheets and sample recovery documentation are presented in Appendix B. 

4.1 Summary of Results 

The table below is a synopsis of the sampling conducted at both locations. 

0 

Summary of Results Kiln Nos. 1 & 2 and ~In No.3/ 

Source Kiln Nos. 1 & 2 

Pollutants Emission Rate, Emission Rate, 

gr/dscf* lbs/hr 

Particulate Matter 0.0104 3.20 

Hydrogen Chloride 0.0020 0.61 

Hydrogen Fluoride 0.0009 0.26 

*grams per dry standard cub1c foot 

4.2 Discussion 

This sampling program was performed to demonstrate compliance of the Brick Kiln Exhaust Nos. 1 & 2 

with regards to Air Quality Permit No. 06897T08 regulations. 

TRIGON ENGINEERING CONSULTANTS, 1NC. LELACCERTIFICATE NO. 04036 Page 16 of 17 
Stationm)' Sm1rce Sampling, Triangle Brick Company 

Brick Kilns I mul 2 Exhausts, ,\Jerry Oaks, North Carolina 

5.0 APPENDICES 

September 1. 2006 

Trigon Project No. 046-06-076 

This section contains detailed supportive documentation that encompasses the relevant aspects of the 

emission test program. Its contents serve as the foundation for the test report. The emission test report 

presents a summary of the information gathered during the sampling activities. The information contained 

in the appendices is necessary to facilitate the review of the emission test report and determine whether 

proper procedures were used to accomplish the test plan objectives. 

Defensible data and the subsequent pollutant concentrations and emission rates is one of the primary 

objectives of any emission test program. To this end, the test results, example calculations, field data sheets, 

sample recovery, laboratory results, chain of custody documentation, and equipment calibrations have been 

provided to support these objectives. 

TRIGON ENGINEERING CONSULTANTS, INC. LELAC CERTIFICATE No. 04036 Page 17 of!? 
1/75 

APPENDIX A 

SUMMARY OF RESULTS AND EXAMPLE CALCULATIONS 
Colby/Triangle Brick 

Merry Oaks. North Carolina 

SUMMARY OF RESULTS 

EPA METHOD 26A 

Trigon Project No. 046-06-076 

Kilns I and 2 Common Scru~/rSQck 

Determination of Hydrogen Halides & Halogens with Particulate Emissions 

Run Number 

Sample Identification 

Date: 

8 

Pbar 

P, 

Vwc 

Bws 

%C02 

%CO 

Md 

M, 

Cp 

L'lPS 

A 

Qso 

Qsw 

D, 

Net Time of Test, minutes 

Sample Time, 24-hour clock 

Barometric Pressure, in. Hg 

Static Pressure, in. Hg 

Stack Pressure, Absolute, in. Hg 

Actual Meter Volume Sampled, cu. ft. 

Avg. Delta H, in. H20 

Avg. Gas Meter Temp., Deg. F 

Volume Sampled at Stand. Cond., cu. ft. 

Volume of Water Collected, ml 

Volume of Water Vapor at Std. Cond.,SCF 

Moisture Content 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 Gas, Dry Basis, lb/lb mole 

Mole. Wt. Stack Gas, Wet Basis, lb!lb mole 

Pitot Tube Constant 

Avg. Sqrt. Delta P, in. H20 

Avg. Stack Temp., Deg. F 

Avg. Stack Velocity, ftisec 

Area Stack, ff 

Gas Volume Flow, Dry Std. Cond. CFM 

Actual Gas Volume Flow, CFM 

Gas Volume Flow, Wet Std. Cond., CFM 

Sample Nozzle Diameter, inches 

i; igUil r~ngintering Consullclnb. ii:C 

2 

6076-02 

08/10/06 

90 

3 4 

6076-03 6076-04 

08/10/06 08/10/06 

90 90 

1002-1136 1152-1324 1334-1508 

29.68 

-0.040 

29.640 

71.374 

2.11 

88.7 

68.486 

154.3 

7.27 

0.096 

9.6 

0.904 

16.60 

2.60 

0.00 

29.080 

28.017 

0.84 

0.712 

472.4 

54.2 

21.82 

35998 

70980 

39818 

0.293 

29.62 

-0.041 

29.579 

73.984 

2.27 

94.7 

70.109 

161.6 

7.61 

0.098 

9.8 

0.902 

16.70 

2.50 

0.00 

29.068 

27.984 

0.84 

0.745 

474.0 

56.9 

21.82 

37531 

74445 

41604 

0.290 

29.59 

-0.040 

29.550 

70.290 

2.05 

93.3 

66.674 

172.2 

8.11 

0.108 

10.8 

0.892 

16.47 

2.73 

0.00 

29.096 

27.892 

0 84 

0.687 

474.1 

52.5 

21.82 

34219 

68750 

38380 

0.293 

Average 

29.63 

-0.040 

29.590 

71.883 

2.14 

92.2 

68.423 

162.7 

7.66 

0.101 

I 0.1 

0.899 

16.59 

2.61 

0.00 

29.081 

27.965 

0.84 

0. 715 

473.5 

54.5 

21.82 

35916 

71391 

39934 

0.292 
Colby/Triangle Brick Trigon Project No. 046-06-076 

Merry Oaks, North Carolina Kilns I and 2 Common Scm!US!Ack 

SUJ'v!MARY OF RESUL IS 

EPA METHOD 26A 

Determination of Hydrogen Halides & Halogens with Particulate Emissions 

Run Number 2 3 4 Average 

A" Area ofNozzle, ft' 0.00047 0.00046 0.00047 0.00047 

I Percent Isokinetic 98.6 98.8 100.9 99.4 

MBNo. Meter Box Number 300.390 300.390 300.390 300.390 

llli@ tlH@ of Meter Box 1.88 1.88 1.88 1.88 

Yq, Alternative Method 5 Posttest Calibration (AL T -009) 1.02 1.03 1.03 1.03 

Front Half Analysis- Non-Condensible Particulate Matter 

m" Non-Condensible Catch, mg 52.4 41.3 45.1 46.3 

C, Non-Condensible Concentration, gr/dscf 0.0118 0.0091 0.0104 0.0104 

c~ Non-Condensible Concentration, gr/acf 0.0113 0.0086 0.0099 0.0099 

CAW Non-Condensible Emission Rate, Jbslhr 3.64 2.92 3.05 3.20 

Hydrogen Chloride Concentration and Emission Rate 

MwHCl Molecular Weight of Hydrogen Chloride, g/mole 36.46 36.46 36.46 36.46 

m"gHCI Hydrogen Chloride Catch, ug 8,180 8,770 9,490 8,813 

m"HCI Hydrogen Chloride Catch, mg 8.18 8.77 9.49 8.81 

C, Hydrogen Chloride Concentration, ppmv 2.78 2.91 3.32 3.00 

em Hydrogen Chloride Concentration, mg/dscm 4.22 4.42 5.03 4.55 

C, Hydrogen Chloride Concentration, gr/dscf 0.0018 0.0019 0.0022 0.0020 

C., Hydrogen Chloride Concentration, gr/acf 0.0018 0.0018 0.0021 0.0019 

CAW Hydrogen Chloride Emission Rate, lbslhr 0.57 0.62 0.64 0.61 

Hydrogen Fluoride Concentration and Emission Rate 

MwHF Molecular Weight of Hydrogen Flouride, g/mole 20.01 20.01 20.01 20.01 

mugHF Hydrogen Flouride Catch, ug 3,870 3,860 3,740 3,823 

m"HF Hydrogen Fluoride Catch, mg 3.87 3.86 3.74 3.82 

C, Hydrogen Fluoride Concentration, ppmv 2.40 2.34 2.38 2.37 

em Hydrogen Fluoride Concentration, mg/dscm 2.00 1.94 1.98 1.97 

C, Hydrogen Fluoride Concentration, gr/dscf 0.0009 0.0008 0.0009 0.0009 

c", Hydrogen Fluoride Concentration, gr/acf 0.0008 0.0008 0.0008 0.0008 

C,w Hydrogen Fluoride Emission Rate, Jbs/hr 0.27 0.27 0.25 0.26 
Colby/Triangle Brick 

Merry Oaks, Nmth Carolina 

SU]VJMARY OF RESULTS 

EPA METHOD 26A 

Trigon Project No. 046-06-076 

Kilns I and 2 Common Scru~/r"lQck 

Determination of Hydrogen Halides & Halogens with Particulate Emissions 

Example Calculations Run 1 

Stack Pressure, Absolute, in. Hg 

Ps=Pbar+Pg= 

Volume Sampled at Stand. Con d., cu. ft. 

17.647 * VM * (Pb., + Ml I 13.6) 

V STD = -------------------------------------------------- = 

TM + 460 

Volume of Water Vapor at Std. Cond.,SCF 

V we~ 0.04709 * Vc ~ 

Moisture Content of Gas Stream 

Vwc 

Bws = ---------------------------------- = 

Ysm + Vwc 

Percent Moisture in Stack 

IOO*Vwc 

PMV = --------------------------- = 

Ysm+Vwc 

Mole Fraction of Dry Gas 

100- PMv 

MFD c=- ----------------------- = 

100 

Mole. Wt. Stack Gas, Dry Basis, lb/lb mole 

M, ~ 0.44 * %C02 + 0.32 * %02 + 0.28 * (I 00- %C02 - %02) ~ 

Mole. Wt. Stack Gas, Wet Basis, lb/lb mole 

Ms ~ M, *(I - Bw,) + 18.0 * Bw, ~ 

Avg. Stack Velocity, ftlsec 

(Ts + 460) 

Vs ~ 85.49 * C, * L'IPS * SQRT -------------------------

(Ps * M,) 

Gas Volume Flow, Dry Std. Cond. CFM 

1058.82 * V, *A* Ps *(I- B.,,) 

Oso ~ --------------------------------------------------- ~ 

T, + 460 

Actual Gas Volume Flow, CFM 

Q, ~ Vs * A * 60 ~ 

Gas Volume Flow, Wet Std. Cond., CFM 

Osw ~ Oso* [1/(l-Bws)] ~ 

Area of Nozzle, fr' 

A"~ ((D" I 2)"' * 3.l4l59)/l44 ~ 

Percent Isokinetic 

0.0945 * (Ts + 460) * Vsm 

[ ~ ----------------------------------------------- ~ 

8 * V5 * P, * (I - B,") *A., 

Trigl)n t=:ngilll:ering Consul!ailh, Inc 

29.640 

68.486 

7.27 

0.096 

9.6 

0.904 

29.080 

28.017 

54.2 

35998 

70980 

39818 

0.00047 

98.6 
Colby/Triangle Brick 

Merry Oaks, North Carolina 

SUMMARY OF RESULTS 

EPA METHOD 26A 

Trigon Project No. 046-06-076 

Kilns I and 2 Conunon Scmilblr"6~ck 

Determination of Hydrogen Halides & Halogens v.:ith Particulate Emissions 

Front Half Analysis- Non-Condensible Particulate Matter 

Non-Condensible Concentration, gr/dscf 

(At Standard Conditions) 

Cs ~ 0.0154 * m" I Ysm ~ 

Non-Condensible Concentration, gr/acf 

(At Standard Conditions) 

C,.~0.0154 * m"/VM~ 

Non-Condensible Emission Rate, lbslhr 

(At Standard Conditions) 

C,w ~ 0.00857 * C, * Qso ~ 

Hydrogen Chloride Concentration and Emission Rate 

Hydrogen Chloride Concentration, ppmv 

C, ~ Cm I MwHCI * 24.05408 ~ 

Hydrogen Chloride Concentration, mg/dscm 

Cm ~ m,,HCI*0.001/ Ysm * 0.0283160502 ~ 

Hydrogen Chloride Concentration, gr/dscf 

Cs ~ 0.0154 * m",HCI *0.0011 YsTD ~ 

Hydrogen Chloride Concentration, gr/acf 

(At Standard Conditions) 

C.,~ 0.0154 * m"HCI/ V" ~ 

Hydrogen Chloride Emission Rate, lbslhr 

(At Standard Conditions) 

C,w ~ 0.00857 < C, * Qso ~ 

Standard Conditions 68 Deg. F, 29.92 in. Hg 

Tri~~Uil [11;;incc:ring: ConsuiLJ11ts, Inc. 

0.0118 

0.0113 

3.64 

2.78 

4.22 

0.0018 

0.0018 

0.57