# PARTICULA TE MATT ER TEST RE PO RT for 

# Han so n Bri ck Columbia, SC

Prep ared

f or : Ha nso n B ric k Eas t, LL C dba H ans on Bri ck

510 0 B ric kya rd R oad Co lu mbi a, S C 292 03 Prep ared

by:

Ai r-Tech E nvi ronmen tal

, LL C P. O. Bo x

12 353 Re sea rch Trian gle Pa rk, N C 277 09-2 353

(919 ) 54 4-63 38 Tes t D ate: October

11, 2006Ai r- TechE

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, LL C pe rson nel and is a tr ue repr esent ation of the res ults obt ained f rom the sam pling prog ram BrickKil ns ESPA P4 K1 an d E S-P 4K2 a t P la nt 4 at the Co lu mbi a, S C faci li ty . The sampl in g and an al ytic al me th o d s w e re p e rfor me d i n a cc o rd a n ce w i th p ro ce d u re s a p p ro v e d b yt h e S ta te o f S o u th Ca rol in a.

T ea m Le ad er: D a rr e l l H . D o e rle , S e n i o r S ta ffS c i e n ti s t D a te
R evi ew er: M i c h a e l W . H a rtm a n , P rin c i p a l S c i e n ti s t D a teAi r- TechE

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### TA BLE OF CONTENTS Pag e
1
. 0 I N T R O D U C T I O N
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2
. 0 R E S U L T S S U M M A RY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 3
. 0 S A M P L I N G A N D A N A L Y T I C A L M E T H O D S
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 4 .0 QU A L ITYA S S U RA N C E / QU A L ITYC ON TR OL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
T able s T a b l e 1
. M e t h o d 5 / 2 0 2 R e s u l t s S u m m a ry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 T a b l e 2
. Q A

S u m m a ry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Figu res Fig ure 1 Proc ess Schem atic, Hanson Brick(Columb ia, SC)
. . . . . . . . . . . . . . . . . . . . . . 5 F i g u re 2 M e t h o d 2 6 A S a m p l i n g T ra i n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Ap pen dices Ap pen di x

A Fi el d D ata Sh eets an d R un Su mmarie s A p p e n d i x

B A n a l yti ca l R e p o rt Ap pen di x

C M eter Ca li brati ons Ap pen di x

D Pro ces s D ocu mentati on Ap pen di x

E Exampl e C al cul ati onsAi r- TechE

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### 1.0 INT ROD UC TION On O cto ber

11, 2006, Air-Tech Environ m ental performe d sam pling at the Han son Brick Col umbia, SC faci li ty

to prov ide faci li ty

personne l w it h the bes t av ail abl e dat a for est imat ing par

ti cul ate matter

( PM ) emis si ons at P lan t 4. Two k il ns ex haust s a re ducted to a com mo n scrubb er (a dry lime ab sorbe r or D LA), to remo v e hydrogen f luoride (HF ) emis si ons from the ex haustst re am. S ampli ng was condu cte d at the e x haustst ack of the D LA t o c haract er iz e emi ss ion s o f f il terabl e par ti cul ate matter

( PM ) uti li z ing the sampl ing procedu re s o f Meth ods 5 and 202. These sampl ing procedu re s a ll ow for t he assessm entof

both f ilterable and cond ensa ble PM f rom e mission sources. A sum ma ry o f t h e re s u lt s is p re s e n t e d in t h e t a b le b e lo w. This repor

t present s t he resul ts of the s ampli ng i n Secti on 2. A desc ri pti on of the sam pling location s and the m eth odo logies emp loyed in emission s characte riz ation s are cont ain ed i n Secti on 3. Se cti on 4 present s a n as ses sment of the q ual ity co ntrol measures tak en dur ing the per formance of thistes t prog ra m.

Ma ssRa te lb/hr lb/ton Outlet Outlet Ru n 1 0.96 1 0.04 9 Ru n 2 1.22 6 0.06 2 Ru n 3 0.82 9 0.04 2 Av erage 1.00 5 0.05 1
M AC Tlimit

is 0.12 lb/ton aAi r- TechE

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### 2. 0 RESULTS SUM M A RY T hree test runs were condu cted for the d ete rmina tion o f PM emission rates. T est sum ma ries are presen ted below. Ef forts w ere m ade , successf ully , to collect all sam ples du ring stea dy prod uction rates of a single ty pe o f

produ ct. Th e brick product ion rate d ur ing the tes ti ng av erag ed 9. 57 to ns per hour ( tph)at Ki ln 1 and 10.09 tph a t Ki ln 2. Total throug hput w as 19.66 tph. Partic ulate Matter Sampl ing Results Par ti cul ate s ampli ng was per formed for the d eter minat ion of both filt erabl e and conde nsabl e PM us ing procedu re s o f Meth od 5 and i ncor porati ng a M ethod 202 conde nsabl e s ampli ng train
. These s ampli ng procedu re s y iel ded t hree par ti cul ate f ra ct io n s a tt h e co m p le t io n o f a n a lys is
. T h e s e f ra ct io n s a re t h e f il t e ra b le P M a n d two conde nsabl e fracti ons, one org ani c a nd one ino rg ani c. A s ummary of the s ampli ng re sul ts is present ed i n Tabl e 1. Av erag e emi ss ion rates of total par ti cul ate matter

were found to be 1. 005 l b/hr
. Fi lt erabl e PM emi ss ion s were found to make u p the g re ates t fracti on of the PM emis si ons, av erag ing ~ 70% of the to tal
. The in org ani c c ondens abl e fracti on made up near ly the enti re remaini ng 30%
.

Tab le 1. M et ho d 5/202 Res ul ts Su mma ry

Run # / Tim e Flo w

(ds cfm ) Flu e Gas Conc ent ra tio n ( gr /ds cf) Emi ssio n Rate (lb/hr) Emi ssio n Ra te (lb /to n)

F CI CO CT T F CI CO CT T T PM PM PM PM PM PM PM PM PM PM PM 1 1033 - 1 136 18,2 87 0.00 46 0.00 14 0.00 014 0.00 15 0.00 61 0.72 6 0.21 2 0.02 2 0.23 5 0.96 1 0.04 9 2 1158 - 1 301 19,0 89 0.00 52 0.00 22 0.00 007 0.00 23 0.00 75 0.84 8 0.36 7 0.01 2 0.37 9 1.22 6 0.06 2 3 1325 - 1 428 19,5 15 0.00 31 0.00 18 0.00 004 0.00 18 0.00 50 0.51 7 0.30 5 0.00 7 0.31 2 0.82 9 0.04 2 Av era ge 18,9 64 0.00 43 0.00 18 0.00 008 0.00 19 0.00 62 0.69 7 0.29 5 0.01 4 0.30 8 1.00 5 0.05 1

F PM = Par t i cul at e m at t er , f i l t er abl e f r act i on CI PM = Par t i cul at e m at t er , cond ensabl e i nor gani c f r act i on CO PM = Par t i cul at e m at t er , cond ensabl e or gani c f r act i on CT PM = Par t i cul at e m at t er , t ot al cond ensabl e f r act i on T F C T PM = T ot al p ar t i cu l at e m at t er( PM + PM )Ai r- TechE

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### 3. 0 SA M PLING A ND A NA LYTICA L M ETHODS The emis si ons w ere c oll ect ed from t he c ommon ex haustst ack of two br ic k k il ns downstream of

a dry lime ab sorbe r emp loyed in HF em issions con trol. Th e proce ss w as cont inu ous w it h a s teady st re am of bri ck

ca rt s e nter ing and lea v ing the ki ln, one car t app ro x imat ely

ev er y 55 mi nutes ( 22 c ars/2 4 hours)
. The ki lnswere fired w it h nat ural gas. Stack gas temp eratu re was ap proximate ly 400 F. o S a m p le s we re co ll e ct e d f ro m a si n gl e ci rc u la r s t a c kt h a tis 5 9 -1 / 2 " in d ia m e t e r. Two sampl ing por

ts 90 apar

t on the s ame pl ane al lowed ac ces s for sa mple col lecti on atan o EPA -met hod accep tab le sam pling location . Th ese p orts w ere ap proximate ly 4" in dia meter
. A s chemat icof the s ampli ng l ocat ion co ntai nin g flow di stu rb ancesand poi nt loc ati on i s p re sent ed i n F ig ure 1. The sampl ing methodsare des cr ibe d i n thi s s ect ion and are the mostrecentrev is ion s of the EP A publ is hed meth ods. Three one- hour sa mples of each ty pe di sc uss ed bel ow w ere c oll ect ed. The emis si on rate o f is re por ted a s flu e g as conc entrati on and pounds per hour
. Product ion data i s a ppended. 3.1 Part

iculat e Sampl in g by EPA Met

ho d 5/202 EPAMethod s 5 and 202 (Appe ndix A, Part 60, T itle 40, Code of Federa l Reg ulatio ns) w ere us ed to measu re par ti cul ate matter

( PM ) emis si ons. Bo th met hods re q uired col lecti on of fil terabl e ( or front -h alf) PM , i n thi s i nst ance, on a heat ed fil ter us ing M ethod 5 guideline s. Th e ba ck half of the sam pling train (impinger wate r) w as use d to collect conde nsabl e PM ac cordin g to Me thod 202. Total PM emi ss ion s were det er mined by summi ng front -h alf, or

fil terabl e PM , and bac k- hal f, or conde nsabl e PM
. 3.1 .1 Principle The PM sa mpli ng train i s s how n i n F ig ure 2. The s ampli ng procedu re ca ll s for PM to be col lected i sok ine ti cal ly

by extract ing the sampl e g as from the sta ck throug h a c ali brated nozz le at t he s peci fied s ample poi nts
. Al l sampl e poi nts were es tabl is hed ac cordin g to EPA Me thod 1. The sampl e s tream pas sed throug h a g las s- li ned probe and throug h a g las s fib er

fil ter , upo n w hic h fil terabl e PM was col lected. The g as then w as direct ed throu gh a series of

chilled w ate r impingers to remo v e an d me asure stack gas moistu re cont ent a s well as to col lect c ondens abl e PM
. Sampl e flow was then direct ed v ia anAi r- TechE

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/pump/or ific e meter

box to measure s ample flow rate and s ample v olu me. T he a mo untof

PM collected o n the f ilter, in impinger cont ent s and in associate d rinses, w as deter mined g ra v imet ri cal ly
. The tota l mass of PM co ll ect ed was div ide d by the g as sampl e v olu me to deter mine PM co ncent ra ti on. Stac k g as flow rates , mol ecul ar

weig ht, and moi stu re co ntent

were det er mined by

EPA R eferenc e M ethods 2, 3 and 4, re specti v ely
. The PM co ncent ra ti on v alu e was mult ipl ied by the sta ck

g as flow rate t o calculat e PM em ission rates in lb/h r. The stack gas flo w rate w as repo rted on a dry basis, co rrected to stand ard con dition s of 1 atm osph ere an d 68 F. o 3.1.2 Pr epar ati on The sampl e train co mponents were c lea ned and ca li brated at A i r - T e ch ’s Research T riangle Park facility . Th e glassware w as clean ed a s follows:

, Soap wash;
, Tap w ater

r ins e; , De- ion iz ed water r ins e; an d
, Me thy len e c hlo ri de. No si li cone g re ases were us ed i n A i r - T e ch ’s sa mpli ng eq uip ment, thereby av oid ing the potent ial for a ny

g las sware c ontami nati on. Al l dr y g as meters a re full y

ca li brated ag ain st an approv ed EP A i nter mediat e s tandard. After compl eti on of the tes t, the accura cy of the m ete r calibrations were conf irmed bya post-te st calibration check. All sam ple no z z les also w ere calibrat ed b y mea suring their inside diam ete r to the ne arest one -thou sand th of

an inch u sing precision calipers. Add itiona l samp ling equipm entis ro uti nel y ca li brated as w ell ( top l oadi ng sc ale s, pit ot t ubes, etc .)
. 3.1.3 Pr eli m ina ry On- Site Measur

em ents Before the s ampli ng r un, s tac k d imens ion s were v er ified , a cy cl oni c flo w chec k/p re li minar

y flow dete rmi nati on made, and sta ck g as mois ture c ontentes ti mated. Stac k g as mois ture c an be est imat ed from e ng ine er ing ca lc ula ti ons or prev iou s d ata accura tely eno ugh to calcula te a suita ble K facto r ( used to det ermin e isokine tic sampl ing rates ). The es ti mated v alu e was then confir med after the firs t r un.Ai r- TechE

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Figu re 1. Pro ces s S che matic, Ha nso n Bric kAi r- TechE

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Fi gu re 2 . Me th od 5/20 2 Sam pl in g TrainAi r- TechE

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. The g las s l ine r w as ins erted i nto t he s ampli ng probe; the fil ter as sembl y

and probe t hen were s eal ed to prev ent a ny co ntami nati on. The impi ng er por ti on of the sampl ing train was ass embled w it h the i mping ers b ein g co nnect ed w it h U -t ube conn ecto rs, and th e inlet an d ou tlet of the im pinger train seale d w ith alum inum foil. The train co mponents were transpo rt ed to the tes t l ocat ion
. A c lea ned and ca li brated sampl ing nozz le w as attac hed t o the probe and the train was ass embled and prepared for the p relimina ry

leak check. 3.1.5 Sam

pli ng Op er ati ons The sampl ing train s were l eak chec ked at t he s tar t and fini sh of sampl ing , t he l atter as re q uired by

the re ferenc e method s. The as sembl ed train was lea k c heck ed before the tes t by ca ppi ng off

the nozz le inl et an d pul li ng a v acuum of appro x imat ely 15 i n. H g on the s yste m. W it h the syste m ev acuat ed, t he volu me of g as flow ing throug h the syste m w as ti med for 6 0 s econd s. The c ri ter ion for a n ac cept abl e l eak ra te was les s t han 0. 02 acfm (ft /min ). Sa mpli ng train s were l eaked ch eck ed w it h the probe and fil ter at the 3 re q uired s ampli ng temperature of ~ 250 F. After a s ucc ess ful l eak chec k, the p ro be was o inserte d into the sta ck w ith the probe nozz le locate d at th e f irst trav erse po int at which ti me sampl ing beg an. Dur ing the sampl e r un, ) P ( v elo ci ty press ure) , ) H (met er , or ific e press ure) , mete r tem pera tures, stack tem pera tures, g as me ter read ings, and sam ple vacuum were re corded at5- minut e i nter v als
. After compl eti on of the final trav erse (o ne full tes t) , t he final l eak chec k was condu cte d. 3.1 .6 Sample Recovery After the p ost -t estl eak chec k, the fil ter was re mov ed and pla ced in a c lea n pet ri di sh, the n ozz le, probe l ine r, and filt er hol der were r ins ed, b ru shed three ti mes w it h ac etone, and pl aced in a g las s s ample jar
. The impi ng er train sa mple re cov er

y was compl eted as cal led for b y

M ethod 202. Thoug h the method re q uires purg ing w hen t he pH me asure s less than 4.5, purging is option al for pH abo v e 4.5 . Althou gh the pH of these sam ples w as >4.5, all samp les w ere pu rg ed. Purges of the con den ser train w ereAi r- TechE

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ni trog en. The impi ng ers t hen were weig hed s o tha t g as mois ture c ontentco uld be d eter mined acc ordin g to EPA Me thod 4. The impi ng er solutio ns the n w ere recovered for cond ensa ble PM. 3.1.7 Gr

avi m etr ic Anal ytical Pr ocedure s f

or Par ticul ate M atter T he followi ng fo ur f raction s were sen t to the laborat oryfor Metho d 5/2 02 a nalysis:

, Fract ion 1 -nozz le, fil ter hol der front -h alf ac etone ri nse: Af ter the v olum e of

the ace ton e rinses w ere de term ined , the y were transfer re d to a pre-w eig hed bea ker , ev aporated to dr y ness , and weig hed to a cons tant w eig ht asdefined in EPA Me thod 5.

, Fraction 2 - f ilter: The filt er was w eig hed t o a c onst ant weig ht asdefined in EPA Me thod 5.

, Fraction 3 - me thylene chlo ride rinse of impinger: After the volu me of fract ion s 3 and 4 had been de ter mined, fracti on 3 w as com bine d w ith f raction 4 in a gl ass sep arato ry f unn el.

, Fraction 4 - imp inger conten ts and wate r r inses of impingers: (Th is fract ion con taine d an y organic and/ or inorganic cond ensa ble particu late m atte r.) Af

ter the v olum e of

f raction 4 had bee n de term ined , it w as transfer re d to a s eparator y funnel alo ng w it h fracti on 3. A sol v ent extract ion was per

formed, c oll ect ing the methy len e c hlo ri de phas e i n a pre-w eig hed bea ker
. The sol v ent e xtract ion procedu re was per formed two addi ti onal ti mes. After extract ion , t he aq ueous phas e was transfer re d to a pre-w eig hed bea ker
. The aq ueous and methy len e c hlo ri de phas es w ere ev aporated to dr

y ness and w eig hed t o a c onst ant weig ht. The resul ts from fracti ons 1 and 2 were c ombine d and re por ted a s f ilterable PM. The results f rom f raction s 3 and 4 w ere repo rted sep arate ly as organic and inorganic cond ensa ble PM respe ctiv elyAi r- TechE

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### 4.0 QU A LITY ASSU RA NC E / QUA LITY C ONT ROL The Qual ity

As surance (QA) procedu re s req uired by the re ferenc e method olo g ies em ployed du ring the testing w ere ad here d to du ring the performa nce o f this test prog ra m. S uch adherence ensures product ion of useful and v ali d dat a throug hout the course of the proje ct. The Q A procedu re s d esc ri bed i n thi s s ect ion representan int eg ra l par

t of the ov erall sa mpli ng and anal yti cal sc heme. The acc eptanc e c ri ter ia, cont ro l li mits , and the re sul ts of these measures obtai ned dur ing thi s t est ing and ana lysis are summ ariz ed in T able 4. A brief discussion of

the QAmea sures is p re s e n t e d b e lo w. QA meas ures tak en to prov ide so me ass ess ment of the q ual ity of sampl e c oll ect ion inc lud ed meas ures of sampl ing rate, and t he as ses sment of the ac curacy of metered gas volum es an d the integrity of samp ling train. Out let sam pling rates, asse ssed a s % is oki neti cs , met method c ri ter ia for al l tes t r uns. Therefore, any sa mple bia s c aused by non represent ati v e c oll ect ion of differi ng par ti cl e s iz es (e it her

par ti cul ate matter

or water drop l et s ) was w i th i n ac c ep ta bl e l i mi ts
. Th e dr y g as me te rs u s ed for

s am pl e v ol um e deter minat ion meet method c ri ter ia for ac curacy . The anal yti cal measu re s o f QA meet the met hod c ri ter ia for reag ent p ur ity , an ass ess ment of the g ra v imet ri c a nal ysi s. Pos ttes t s ample train l eak chec ks meet the met hod c ri ter ia for al l tes t r uns. Tab le 2. QA

Su mma ry
C rite ria C o n tro l L im it R e s u lt % I soki net i cs 100% ± 10% 101 - 105 % D r yG as M et erC al i br at i on: Pr e- t est  d = 1. 00 ± . 02 1. 0046 Post - t est  d = ± 5% - 3. 7% Sam pl e T r ai n Le ak R at e < 0
. 02 cf m 0. 00 - 0. 00
Acet one Bl ank < 0
. 001 wt % 0. 0007% W at erBl ank < 0
. 001 wt % 0. 0004% M et hy l ene C hl or i de Bl ank < 0
. 001 wt % 0. 0003%