PARTICULATE MATTER

TEST REPORT

for

Hanson Brick

Columbia, SC

Prepared for:

Hanson Brick East, LLC dba Hanson Brick

5100 Brickyard Road

Columbia, SC 29203

Prepared by:

Air-Tech Environmental, LLC

P. O. Box 12353

Research Triangle Park, NC 27709-2353

(919) 544-6338

Test Date: October 11, 2006
Air-Tech Environmental, LLC

Hanson Brick/Columbia PM Test Report (AT06-0396-HBC)

Test Date: 10/11/2006 - Page ii 

Air-Tech Environmental, LLC

Report Certification

This report has been reviewed by the following Air-Tech Environmental, LLC personnel

and is a true representation of the results obtained from the sampling program Brick Kilns ESPAP4K1 and ES-P4K2 at Plant 4 at the Columbia, SC facility. The sampling and analytical

methods were performed in accordance with procedures approved by the State of South

Carolina.

Team Leader:

Darrell H. Doerle, Senior Staff Scientist Date

Reviewer:

Michael W . Hartman, Principal Scientist Date
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TABLE OF CONTENTS

Page

1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.0 RESULTS SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3.0 SAMPLING AND ANALYTICAL METHODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

4.0 QUALITY ASSURANCE/ QUALITY CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Tables

Table 1. Method 5/202 Results Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Table 2. QA Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Figures

Figure 1 Process Schematic, Hanson Brick (Columbia, SC) . . . . . . . . . . . . . . . . . . . . . . 5

Figure 2 Method 26A Sampling Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Appendices

Appendix A Field Data Sheets and Run Summaries

Appendix B Analytical Report

Appendix C Meter Calibrations

Appendix D Process Documentation

Appendix E Example Calculations
Air-Tech Environmental, LLC

Hanson Brick/Columbia PM Test Report (AT06-0396-HBC)

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1.0 INTRODUCTION

On October 11, 2006, Air-Tech Environmental performed sampling at the Hanson Brick

Columbia, SC facility to provide facility personnel with the best available data for

estimating particulate matter (PM) emissions at Plant 4. Two kilns exhausts are ducted

to a common scrubber (a dry lime absorber or DLA), to remove hydrogen fluoride (HF)

emissions from the exhaust stream. Sampling was conducted at the exhaust stack of

the DLA to characterize emissions of filterable particulate matter (PM) utilizing the

sampling procedures of Methods 5 and 202. These sampling procedures allow for the

assessment of both filterable and condensable PM from emission sources. A summary

of the results is presented in the table below.

This report presents the results of the sampling in Section 2. A description of the

sampling locations and the methodologies employed in emissions characterizations are

contained in Section 3. Section 4 presents an assessment of the quality control

measures taken during the performance of this test program. 

Mass Rate

lb/hr lb/ton

Outlet Outlet

Run 1 0.961 0.049

Run 2 1.226 0.062

Run 3 0.829 0.042

Average 1.005 0.051

 MACT limit is 0.12 lb/ton a
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2.0 RESULTS SUMMARY

Three test runs were conducted for the determination of PM emission rates. Test

summaries are presented below. Efforts were made, successfully, to collect all

samples during steady production rates of a single type of product. The brick

production rate during the testing averaged 9.57 tons per hour (tph) at Kiln 1 and 10.09

tph at Kiln 2. Total throughput was 19.66 tph.

Particulate Matter Sampling Results

Particulate sampling was performed for the determination of both filterable and

condensable PM using procedures of Method 5 and incorporating a Method 202

condensable sampling train. These sampling procedures yielded three particulate

fractions at the completion of analysis. These fractions are the filterable PM and two

condensable fractions, one organic and one inorganic. A summary of the sampling

results is presented in Table 1.

Average emission rates of total particulate matter were found to be 1.005 lb/hr. 

Filterable PM emissions were found to make up the greatest fraction of the PM

emissions, averaging ~70% of the total. The inorganic condensable fraction made up

nearly the entire remaining 30%.

Table 1. Method 5/202 Results Summary

Run # /

Time

Flow

(dscfm)

Flue Gas Concentration (gr/dscf)

Emission Rate

 (lb/hr)

Emission

Rate

(lb/ton)

PMF PMCI PMCO PMCT PMT PMF PMCI PMCO PMCT PMT PMT

1

1033 - 1136 18,287 0.0046 0.0014 0.00014 0.0015 0.0061 0.726 0.212 0.022 0.235 0.961 0.049

2

1158 - 1301 19,089 0.0052 0.0022 0.00007 0.0023 0.0075 0.848 0.367 0.012 0.379 1.226 0.062

3

1325 - 1428 19,515 0.0031 0.0018 0.00004 0.0018 0.0050 0.517 0.305 0.007 0.312 0.829 0.042

Average 18,964 0.0043 0.0018 0.00008 0.0019 0.0062 0.697 0.295 0.014 0.308 1.005 0.051

PMF = Particulate matter, filterable fraction

PMCI = Particulate matter, condensable inorganic fraction

PMCO = Particulate matter, condensable organic fraction

PMCT = Particulate matter, total condensable fraction

PMT F = Total CT particulate matter (PM + PM )
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3.0 SAMPLING AND ANALYTICAL METHODS

The emissions were collected from the common exhaust stack of two brick kilns

downstream of a dry lime absorber employed in HF emissions control. The process

was continuous with a steady stream of brick carts entering and leaving the kiln, one

cart approximately every 55 minutes (22 cars/24 hours). The kilns were fired with

natural gas. Stack gas temperature was approximately 400 F. o

Samples were collected from a single circular stack that is 59-1/2" in diameter. Two

sampling ports 90 apart on the same plane allowed access for sample collection at an o

EPA-method acceptable sampling location. These ports were approximately 4" in

diameter. A schematic of the sampling location containing flow disturbances and point

location is presented in Figure 1.

The sampling methods are described in this section and are the most recent revisions

of the EPA published methods. Three one-hour samples of each type discussed below

were collected. The emission rate of is reported as flue gas concentration and pounds

per hour. Production data is appended.

3.1 Particulate Sampling by EPA Method 5/202

EPA Methods 5 and 202 (Appendix A, Part 60, Title 40, Code of Federal Regulations)

were used to measure particulate matter (PM) emissions. Both methods required

collection of filterable (or front-half) PM, in this instance, on a heated filter using Method

5 guidelines. The back half of the sampling train (impinger water) was used to collect

condensable PM according to Method 202. Total PM emissions were determined by

summing front-half, or filterable PM, and back-half, or condensable PM. 

3.1.1 Principle

The PM sampling train is shown in Figure 2. The sampling procedure calls for PM to be

collected isokinetically by extracting the sample gas from the stack through a calibrated

nozzle at the specified sample points. All sample points were established according to

EPA Method 1. The sample stream passed through a glass-lined probe and through a

glass fiber filter, upon which filterable PM was collected. The gas then was directed

through a series of chilled water impingers to remove and measure stack gas moisture

content as well as to collect condensable PM. Sample flow was then directed via an
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umbilical hose to the dry gas meter/pump/orifice meter box to measure sample flow rate

and sample volume.

The amount of PM collected on the filter, in impinger contents and in associated rinses,

was determined gravimetrically. The total mass of PM collected was divided by the gas

sample volume to determine PM concentration. Stack gas flow rates, molecular weight,

and moisture content were determined by EPA Reference Methods 2, 3 and 4,

respectively. The PM concentration value was multiplied by the stack gas flow rate to

calculate PM emission rates in lb/hr. The stack gas flow rate was reported on a dry

basis, corrected to standard conditions of 1 atmosphere and 68 F. o

3.1.2 Preparation

The sample train components were cleaned and calibrated at Air-Tech’s Research

Triangle Park facility. The glassware was cleaned as follows:

, Soap wash;

, Tap water rinse;

, De-ionized water rinse; and

, Methylene chloride.

No silicone greases were used in Air-Tech’s sampling equipment, thereby avoiding the

potential for any glassware contamination. All dry gas meters are fully calibrated

against an approved EPA intermediate standard. After completion of the test, the

accuracy of the meter calibrations were confirmed by a post-test calibration check. All

sample nozzles also were calibrated by measuring their inside diameter to the nearest

one-thousandth of an inch using precision calipers. Additional sampling equipment is

routinely calibrated as well (top loading scales, pitot tubes, etc.). 

3.1.3 Preliminary On-Site Measurements

Before the sampling run, stack dimensions were verified, a cyclonic flow

check/preliminary flow determination made, and stack gas moisture content estimated. 

Stack gas moisture can be estimated from engineering calculations or previous data

accurately enough to calculate a suitable K factor (used to determine isokinetic

sampling rates). The estimated value was then confirmed after the first run.
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Figure 1. Process Schematic, Hanson Brick
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Figure 2. Method 5/202 Sampling Train
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3.1.4 Assembling the Train

The first step in assembling the train was to load a pre-weighed filter into the filter

holder. The glass liner was inserted into the sampling probe; the filter assembly and

probe then were sealed to prevent any contamination. The impinger portion of the

sampling train was assembled with the impingers being connected with U-tube

connectors, and the inlet and outlet of the impinger train sealed with aluminum foil.

The train components were transported to the test location. A cleaned and calibrated

sampling nozzle was attached to the probe and the train was assembled and prepared

for the preliminary leak check.

3.1.5 Sampling Operations

The sampling trains were leak checked at the start and finish of sampling, the latter as

required by the reference methods. The assembled train was leak checked before the

test by capping off the nozzle inlet and pulling a vacuum of approximately 15 in. Hg on

the system. With the system evacuated, the volume of gas flowing through the system

was timed for 60 seconds. The criterion for an acceptable leak rate was less than 0.02

acfm (ft /min). Sampling trains were leaked checked with the probe and filter at the 3

required sampling temperature of ~250 F. After a successful leak check, the probe was o

inserted into the stack with the probe nozzle located at the first traverse point at which

time sampling began.

During the sample run, )P (velocity pressure), )H (meter, orifice pressure), meter

temperatures, stack temperatures, gas meter readings, and sample vacuum were

recorded at 5-minute intervals. After completion of the final traverse (one full test), the

final leak check was conducted.

3.1.6 Sample Recovery

After the post-test leak check, the filter was removed and placed in a clean petri dish,

the nozzle, probe liner, and filter holder were rinsed, brushed three times with acetone,

and placed in a glass sample jar. The impinger train sample recovery was completed

as called for by Method 202. Though the method requires purging when the pH

measures less than 4.5, purging is optional for pH above 4.5. Although the pH of these

samples was >4.5, all samples were purged. Purges of the condenser train were
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performed using cylinder nitrogen. The impingers then were weighed so that gas

moisture content could be determined according to EPA Method 4. The impinger

solutions then were recovered for condensable PM.

3.1.7 Gravimetric Analytical Procedures for Particulate Matter

The following four fractions were sent to the laboratory for Method 5/202 analysis:

, Fraction 1 - nozzle, filter holder front-half acetone rinse:

After the volume of the acetone rinses were determined, they were

transferred to a pre-weighed beaker, evaporated to dryness, and weighed

to a constant weight as defined in EPA Method 5.

, Fraction 2 - filter:

The filter was weighed to a constant weight as defined in EPA Method 5.

, Fraction 3 - methylene chloride rinse of impinger:

After the volume of fractions 3 and 4 had been determined, fraction 3 was

combined with fraction 4 in a glass separatory funnel.

, Fraction 4 - impinger contents and water rinses of impingers:

(This fraction contained any organic and/or inorganic condensable

particulate matter.) After the volume of fraction 4 had been determined, it

was transferred to a separatory funnel along with fraction 3. A solvent

extraction was performed, collecting the methylene chloride phase in a

pre-weighed beaker. The solvent extraction procedure was performed

two additional times. After extraction, the aqueous phase was transferred

to a pre-weighed beaker. The aqueous and methylene chloride phases

were evaporated to dryness and weighed to a constant weight.

The results from fractions 1 and 2 were combined and reported as

filterable PM. The results from fractions 3 and 4 were reported separately

as organic and inorganic condensable PM respectively
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4.0 QUALITY ASSURANCE / QUALITY CONTROL

The Quality Assurance (QA) procedures required by the reference methodologies

employed during the testing were adhered to during the performance of this test

program. Such adherence ensures production of useful and valid data throughout the

course of the project. The QA procedures described in this section represent an

integral part of the overall sampling and analytical scheme. The acceptance criteria,

control limits, and the results of these measures obtained during this testing and

analysis are summarized in Table 4. A brief discussion of the QA measures is

presented below.

QA measures taken to provide some assessment of the quality of sample collection

included measures of sampling rate, and the assessment of the accuracy of metered

gas volumes and the integrity of sampling train. Outlet sampling rates, assessed as %

isokinetics, met method criteria for all test runs. Therefore, any sample bias caused by

non representative collection of differing particle sizes (either particulate matter or water

droplets) was within acceptable limits. The dry gas meters used for sample volume

determination meet method criteria for accuracy. The analytical measures of QA meet

the method criteria for reagent purity, an assessment of the gravimetric analysis. Posttest sample train leak checks meet the method criteria for all test runs. 

Table 2. QA Summary

Criteria Control Limit Result

% Isokinetics 100% ± 10% 101 - 105%

Dry Gas Meter Calibration:

Pre-test d = 1.00 ± .02 1.0046

Post-test d = ± 5% - 3.7%

Sample Train Leak Rate < 0.02 cfm 0.00 - 0.00

Acetone Blank < 0.001 wt% 0.0007%

W ater Blank < 0.001 wt % 0.0004%

Methylene Chloride Blank < 0.001 wt % 0.0003%