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 
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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. , 

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: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. 

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19-carolinaceramics.doc 

DAVIS & FLOY®, INC. 
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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 m3/35.31 ft' x 60 min/hr. 

NOTE 1: Standard cubic feet per minute at 29.92 inches of inercury and 68 degrees F. 

HZ SOy0.1N 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 3x 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. 

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®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. 
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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 

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' 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) 

tttack 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 

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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) 

'ittot 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 

tackgas 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 

cozzle diameter (DN) 0.3400 0.3400 0.3400 0.3400 

rjea 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 

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DAVIS & FLOYD INC. 

01- 1 

POST OFFICE DRAWER 428 

bmi GREENWOOD, SOUTH CAROLINA 29648 

***#+***********##t************k*#+#* 

SOURCE SAMPLING DATA SUMMARY'** 

*********k*****************t*#*****## 

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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 

kVG 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 Otack 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