## 12ODS HF EMISSION EVALUATION KILN NO. 3 AND KILN NO. 4 CAROLINA CERAMICS COLUMBIA, SOUTH CAROLINA

# D AYI S Engineering

= Architectare 

# FLd

~ 

# Y Environmental R Laboratory Services
Davls & Floyd, Inc. • P.O. Drawer 428 Greenwood, SC 29648 • 816 East Durst Avenue Greenwood, SC 29649 •(864) 229-4413 (office) (864) 229-7119 (frnc)


### December.l9, 2005 Serial No. HGA-122-05 Job No.: 62419.00

Mr. Ken Newell Carolina Ceramics 9931 Two-Notch Road Columbia, SC 29223-4390 Reference: Emission Testing on Fluoride Cascade Absorber Dear Mr. Newell: Davis & Floyd, Inc. conducted source test sampling at Carolina Ceramics, Columbia, South Carolina, on October 18 and November 30, 2005. These tests were conducted for hydrogen fluoride on the outlet gases of Kilns No. 3 and 4, respectively. Two copies of the report containing the results of this project are enclosed. A copy of this report should be mailed to the South Carolina Department of Health and Environmental Control, Bureau of Air Quality, 2600 Bull Street, Columbia, SC, 29201. We would like to express our appreciation to you and the Carolina Ceramics personnel involved in this project for their assistance in tlre areas of scheduling, physical arrangements, etc. Should you have any questions regarding this work or report, or if we may be of additional assistance, please do not hesitate to contact us. 

### Sincerely, DAVIS & FLOYD, INC.

H. Gary Anderson, Jr. Field Services 

### Environmental Division Enclosures: As stated in letter

# ~

~ ~I ~i

~

~I l

C TABLE OF CONTENTS

1.0 INTRODUCTION 2.0 TEST OBJECTIVES 3.0 PROCESS DESCRIPTION 4.0 SAMPLING AND ANALYTICAL PROCEDURES 4.1 Velocity Traverse Point Locations 4.2 Volumetric Flow Rate 4.3 Moisture and Molecular Weight 4.4 Hydrogen Fluoride 5.0 SAMPLING RESULTS Table 5.1 Hydrogen Fluoride Emission Results, Kiln No. 3 Table 5.2 Hydrogen Fluoride Emission Results, Kiln No. 4



## APPENDICES APPENDIX I EPA Method 26A Data Reduction APPENDIX 2 Calculations APPENDIX 3 

### Field Data Field Equipment Calibrations APPENDIX 4 Laboratory Data Production Data 

### PAGE

2.1 3.1 4.1 4.1 4.1 4.1 4.1 

### 5.1

DAVIS & FLOYD, INC.

### 1.1

1.0 INTRODUCTION Carolina Ceramics, located in Columbia, South Carolina, is a manufacturer of ceramic brick. A part of this process is the drying or curing of the brick, which is done in ovens referred to as kilns. On October 18 and November 30, 2005, emission test were conducted for hydrogen fluoride on the outlet gases of Kilns 3 and 4, respectively. Stanley Broome and Brandon Wilson of Davis & Floyd, Inc. performed this 

### testing.

H \ADMINDAT\pLOTHRIDINGA\05\Reports\62419-carolinaceramics.doc

~ — 

### DATI3 Rr FLOYD, INC.

### 2.1

2.0 TEST OBJECTIVES The objective of this testing was to demonstrate compliance with South Carolina Department of Health and Environmental Control (SCDHEC) established air standards for hydrogen fluoride using EPA Method 26A (Determination of Hydrogen Halide and Halogen Emissions from Stationary Sources — Isokinetic Method).

H:W DMRJDAT\PLOTHRID\HGA\05\Reports\624I9-carolinaceramics.doc 

### DAVIS 8 FLOYD, INC.

### 3.1 

### R 3.0 PROCESS DESCRIPTION

This process is the firing of dried brick products 31.27 hours from entrance of kiln to exiting kiln through 

# ~ an "intermittent push" ttlnnel kiln. Intermittent push is defined as moving tlte product a certain distance 

# ~ throtigh the kiln and then holding the product stationary for a specific amount of time. 'fhe product does

not move on a continuous basis. The kiln sections are described as follows: Pre-heat Section, Firing 

# ~ Section, Quick Cool Section, and Slow Cool Section. During the preheating of the product, fluorine, 

# ~ which is present in the raw Inaterial, is released and combines with hydrogen inside the kiln and forms

gaseous hydrogen fluoride. This hydrogen fluoride is then exhausted into a duct and travels throtlglt



# ~ l stacked beds of limestone. The hydrogen fluoride reacts with the limestone to form calcium fluoride. The 

# I I clean air is then exhausted into the atmosphere.

The Designed Rate is 207.9 tons/day fired. The Test Rate: 193.5 tons/day fire for Kiln No. 3 and 184.8 tons/day fired for Kiln No. 4. 

# ~1



# ~ J The production rate for the kiln, in tons per hour, was recorded by Carolina Ceramics personnel for the ( test as follows:

Push Speed x Brick Per Car x Average Weight of Unit = 2000 = Fired Tonnage Rate 

# (~

` 

### This fluorine cascade absorber is mantlfactured by Hellmich. It is a Model No. 1528. The flue gas is Ii 

### conducted via a pipeline to a collecting hood. In the hood, the flue gases are distributed over the flue gas 

# ~ cascades of roof-shape design. From there, the gases flow through uniformly poured crushed limestone

granules into the cleaned gas cascades. During this, the crushed limestone absorbs the HF contained in the flue gas. From the cleaned gas cascades, the cleaned exhaust air is conducted in a pipeline further via a collecting hood to the fan. The crushed used limestone is discharged intermittently via a screw mveyor. The crushed limestone stored in a storage silo subsides at the same'time. To ensure that the

19-carol in aceramics.doc 

### DAVIS & FLOYD, WC.

### 3.2

flue and cleaned gas cascades are always fully covered, they must be topped up with crushed limestone within a suitable period of time. The storage silos are filled by means of pneumatic trucks. The delivery air is filtered through the poured limestone and taken to the cleaned gas hood. The FCA is insulated in order to avoid loss of heat through the outer skin of the absorber.

There are no stack gas or opacity monitoring systems associated with the dry lime sorption scrubber.

A time control system associated with the discliarge of spent lime from the scrubber ensures that the limestone continues to fall down evenly from the atorage silo over the cascades, thus making sure that adsorption of the hydrogen fluoride and the utilization of the limestone granules are optimal. The control monitors are as follows: Pressure drop across scrubber, Thermocouple, and lime purge cycle.

During the emission test, the process rate and kiln temperature of the kiln were recorded by Carolina Ceramics personnel. It was the responsibility of the kiln supervisor to collect this information.

19-carol i naceramics. doc DAVIS & BLOYD, iNC.

### 4.1

4.0 SAMPLING AND ANALYTICAL PROCEDURES 4.1 Velocity Trayerse Point Locations The velocity traverse point locations were selected in accordance with EPA Method 

### 1, "Sample and Velocity Ti-averses for Stationary Sotn-ces". The scrubber exhaust is equipped with a circular stack that is 48 inches in diameter. Two sample ports were Iocated on the circumference of the stack at a location that was approximately 42 feet downstream of the nearest flow disturbance and 11.5 feet upstream from the top of the stack. Twelve (12) traverse points were selected for velocity determinations, 6 along each sample port cross-section (see Figure 1).

4.2 Volumetric Flow Rate Stack gas volumetric flow rate was determined in accordance with EPA Method 2, 

### "Determination of Stack Gas Yelocity and Yolznnetric Flotiv Rate". This was performed in conjunction with EPA Method 26A.

4.3 Moisture and Molecular Weieht Stack gas moisture content was deterinined as per EPA Method 

### 4, "Determination of Moisture Content in Stack Gases" in conjanction witli EPA Metliod 26A. Stack gas molecular weight was determined by obtaining samples and analyzing for oxygen and carbon dioxide concentrations using a Sprint Telegan 1000 combustion analyzer.

Fluoride was determined in apcordance witli EPA Method 26A, 

### "Detezrmination of Halide and Halogen En issions ftorri Stationary Sources - Isokinetic Method'. Three test runs were conducted. The sainple train consisted of a one-piece glass-lined probe glass nozzle, a glass fiber filter (Teflon mat, Pallflex), EPA Method 5 glass impingers, and

DAVIS 8 FLOYD, INC.

### 4 FT. DIA. , ® -- ~

:ters=2.88 meters=10.65

Y, 

### Distance

2.11 7.00 14.2 33.7' 40.9 45.8 

### FIGURE 1 SAMPLE PORT LOCATIONS OUTLET EXHAUST Kiln #3 and Kiln #4 CAROLINA CERAMICS COLUMBIA, SOUTH CAROLINA

# 7

4.2

an EPA Method 5 control console. The first impinger contained 50 ml of 0.1 N sulfuric acid, the third and fourth impingers each contained 100 ml O.IN sulfuric acid, and the fiftb impinger contained 200 milligrams of silica gel. After the testing was completed, the samples were 

# ~ transported to the laboratory where the volume of the impinger catch was measured, the silica gel 

# ~ was weighed, and the impinger solution was transferred to EPA protocol washed glass sample

bottles. The impingers were then rinsed with a known volume of D. I, water, and the rinse was combined with the samples. The samples were then analyzed using ion chromatography as specified in the method. 

# r 1

~

19-carolinaceramics.doc 

### DAVIS & FLOY®, INC.

# 1 5.1

5.0 SAMPLING RESULTS On October 18 and November 30, 2005, stack gas emission studies were conducted at Carolina Ceramics, Columbia, South Carolina. The results of this testing are found in Tables 5.1 and 5.2. TABLE 5.1 Hydrogen Fhioride Emission Results

Kiln No. 3 Carolina Ceramics Columbia, South Carolina Test conducted: October 18, 2005

Emission Rate (]b/hr) Run #1 0.2489 Run #2 0.2398 Run #3 0.1854 Average 0.2247 Calculations: 1. Lbs/hr= I Ib/454',000 mg x mg/m' x Std. Ft. 3 /Min x m 3 /35.31 ft' x 60 min/hr. NOTE 1: Standard cubic feet per minute at 29.92 inches of inercury and 68 degrees F. H Z SO y 0.1N Blank = <I 100 Micrograms HF D.I. Water Blank = <1100 Micrograms HF NOTE 2: (<) Note =1ess than the detection Iimit for the method and/or instrument. TABLE 5.2 Hydrogen Fluoride Emission Results

Kiln No. 4 Carolina Ceramics Columbia, South Carolina Test conducted: November 30, 2005

Emission Rate Ibs/hr Run#1 0.1631 Run #2 0.1517 Run #3 0.1413 Average 0.1520 Calctilations: 1.Lbs/hr = 1 Ib/454,000 mg x mg/m 3 x Std. Ft.'/Min x m'/35.31 ft' x 60 min/hr. NOTE 1: Standard cubic feet per minute at 29.92 inches of inercury and 68 degrees F. H2SO4 O.1N Blank = Q 100 Micrograms HF D.I. Water Blank = <1100 Micrograms HF j NOTE 2: (<) Note =1ess than the detection limit for the method and/or instrument. 

# I E

®AVIS & FLOYD, IYC.

### APPENDIX 1 EPA Method 26A Data Reduction

H: W.DM INDA

- IIPLOTHRID\HGA\05\Reports\62419-carol inaccram ics.doc 

### DAVIS & FLOYD, INC.!

.~ .. n .... : 

# U OR: Carolina Ceramics OCATION: Columbia, SC SOURCE: Kiln # 3 Exhaust 

## DAVIS & FLOYD INC.

POST OFFICE DRAWER 428 GREENWOOD, SOUTH CAROLINA 29648

*** SOURCE SAMPLING DATA SUMMARY ***

TEST METHOD: SAMPLE DATE: DAVIS &FLOYD, INC. JOB#: EPA Method 26A 10/18105 62419.00 

### '~ 

## ' MAn . '* 

### 7EST ~~~ 

# K "/u CO2 a fo 02 11.20 17.30 11.30 17.20 11.00 17.40 11.1 i 17.3( % CO 0.00 0.00 0.00 0.0( N2 71.50 71.50 71.60 71,5 ~ 

# Ot -" o %

~ ry molecular weight (MD) 30.48 30.50 30.46 30.4E Final impinger volume (VF) 310.0 302.0 300.0 304.0 ; I

~ nitial impinger volume (VI)

~ ilica geI vol. increase (VS GEL) 250.0 10.0 250.0 11.6 250.0 11.3 250.0 11.0 --; o tall moisture collected (VIC) 70.0 63.6 61.3 65.0 Total moist. collected (VM STD) 

### t ttack gas moist.content (B WO) 3.3040 9.232 3.0019 8.360 2.8934 8.186 3.0664 8.593 peter dry gas volume (VM) 33.335 34.652 34.812 34.266 Barometric pressure (P BAR) 29.40 29.40 29.40 29.40 gas meter temp (TM) 73.6 87.6 97.8 86.3 

# K ry

~ eter 

### ry gas orifice pressure (DELTA) 1.028 1.076 1.047 1.050 dry gas volume (VM STD). 32.4833 32.9047 32.4518 32.6132

i ( ack gas moist.content (B WO) et molecular weight (MS) 'i t tot coefficient (CP) 0.0923 29.3314 0.0836 29.4513 0.0819 29.4363 0.0859 29.4064 0.84 0.84 0.84 0.84 Avg stack gas temp (TS AVG) 

# 0 aVG SQ/R DELTA P) 336.6 0.3521 337.8 0.3552 336.9 0.3470 337.1 0.3514 . +tatic stack pres. (STATIC P) - -0.150 -0.150 -0.150 -0.150 Pressure of stack (PS) 29.3890 29.3890 29.3890 293890 ttack gas velocity (VS) 24.3037 24.4912 23.9146 24.2365 r oss-sectional stack area (A) 12.5664 12.5664 12.5664 12.5664 Stack gas flow (QS STD CFM) 10829.0641 11001.3124 10774.0166 10868.1310 tack gas flow (QS ACFM) 18324.5924 18465.9328 18031.2196 18273.9149 et bulb te,mp (WB/T) N/A N/A N/A N/A F gain (MN) 5.6550 5.4330 4.2310 5.1063 HF concent. (C/S) 

# OK //S @

~ a12 CO2 0.0027 0.0029 0.0025 0.0027 0.0020 0.0022 0.0024 N/A . cFemission rate (CS) 0.2489 0.2398 0.1854 0.2247 Total Sampling Time (TIME) 60.0 60.0 60.0 60.0 c ozzle diameter (DN) 0.3400 0.3400 0.3400 0.3400 r jea of nozzle (AN) 6.3050E-04 6.3050E-04 6.3050E-04 6.3050E-04 Percent isokinetic (1) 99.68 99.40 100.10 99.72 

### I":r '

# i DAVIS & FLOYD INC.

- 

# 01 1 POST OFFICE DRAWER 428 bmi GREENWOOD, SOUTH CAROLINA 29648
***#+***********##t************k*#+#* SOURCE SAMPLING DATA SUMMARY'** *********k*****************t*#*****##



# ~ L l OR: Carolina Ceramics TEST METHOD: EPA Method 26A OCATION: Columbia, SC SAMPLE DATE: 11130105 SOURCE: Kiln #4 Exhaust DAVIS &FLOYD. INC. JOB#: 62419.00 

# O , ro CO2 5.00 5.20 4.80 5.00 ;-'10 02 15.80 15.50 15.90 15.73 % CO 0.00 0.00 0.00 0.00 

# 0 ' ( o N2 79.20 79.30 79.30 79.27 ,ry molecular weight (MD) 29.43 29.45 29.40 29.43 Final impinger volume (VF) 329.0 322.0 322.0 324.3 Vtial impinger volume (VI) 250.0 250.0 250.0 250.0 Wilica gel vol. increase (VS GEL) 7.8 7.2 5.6 6.9 fotal moisture collected (VIC) 86.8 79.2 77.6 81.2 Total moist. collected (VM STD) 4.0970 3.7382 3.6627 3.8326 

# k 4 tack gas moist.content (B WO) 10.946 10.751 10.793 10.830 n eter dry gas volume (VM) 33.628 32.401 32.239 32.756 Barometric pressure (P BAR) 29.45 29.45 29.45 29.45 ry gas meter temp (TM) 65.5 83.7 94.5 81.2 ,, ry gas orifice pressure (DELTA) 1.029 0.918 0.880 0.943 Meter dry gas uolume (VM STD) 33.3320 31.0316 30.2726 31.5454 tack gas moist.content (B WO) 0.1095 0.1075 0.1079 0.1083 

## 19, Vet molecuiar weight (MS) 28.1807 28.2208 28.1731 28.1915 rJitot coefficient (CP) 0.84 0.84 0.84 0.84 Avg stack gas temp (TS AVG) 407.5 408.1 411.8 409.1 

## k VG SQ/R DELTA P) 

# ~ = 0.3720 0.3460 0.3365 0.3515 tatic stack pres. (STATIC P) -0.180 -0.180 -0.180 -0.180 Pressure of stack (PS) 29.4368 29.4368 29.4368 29.4368 

# O tack gas velocity (VS) 27.3166 25.3998 24.7765 25.8310 ross-sectional stack area (A) 12.5664 12.5664 12.5664 12.5664 Stack gas flow (QS STD CFM) 10983.3288 10228.0880 9930.4643 10380.6271 tack gas flow (QS ACFM) 20596.2207 19151.0260 18681.0549 19476.1005 et bulb temp (WBlT) N/A N/A N/A N/A 

# ~ HF gain (MN) 

# ~ 3.7500 3.4860 3.2630 3.4997 oancent. (C/S) 0.0017 0.0017 0,0017 0.0017



# ~ F /S @%12 CO2 0.0042 0.0040 0.0041 N/A



# ~ ,(F emission rate (CS) 0.1631 0.1517 0.1413 0.1520 Tota1 Ssmpling Time (TIME) 60.0 60.0 60.0 60.0 ozzle diameter (DN) 

# ~ 0.3390 0

. 3390 0.3390 0.3390 rea af nozzle (AN) 6.2680E-04 6.2680E-04 6.2680E-04 6.2680E-04 t Percerit isokinetic (1) 101.44 101.41 101.90 101.59