# Lafarge Building Materials, Inc.

Ravena, New York

March 30, 2010 

# Main Kiln Exhaust Source Emission Testing SOURCE EMISSION TEST REPORTSOURCE EMISSION TEST REPORT

360° Engineering and Project Delivery Solutions 

# Main Kiln Exhaust

Source Emission Testing

Lafarge Building Materials, Inc.

Ravena, New York

DAVE OSTASZEWSKI, P.E., SENIOR MANAGING ENGINEER

O’Brien & Gere Engineers, Inc. 14198 │ 45892

PATRICK GRADY, PROJECT ASSOCIATE

O’Brien & Gere Engineers, Inc.MAIN KILN EXHAUST SOURCE EMISSION TESTING

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# TABLE OF CONTENTS

Table of Contents

............................................................................................................................... ................................ 1

List of Tables ................................................

............................................................... ............................................................... ................ 1

List of Appendices ............................................

............................................................... ............................................................... ......... 1

1. Introduction and Background

............................................................................................................................... ... 2

1.1.  Emissions Testing Pr ogram Participants ..................

............................................................... ............................................ 2

2. Source Description and Process Operating Data

................................................................................................ 3

2.1.  Process Description .....................................

............................................................... ............................................................... .... 3

2.2.  Sampling Location Description ...........................

............................................................... ...................................................... 3

2.3.  Operating Parameters ....................................

............................................................... ............................................................... 3

3. Summary of Test Program

............................................................................................................................... .......... 4

3.1.  Test Program Summary ....................................

............................................................... ........................................................... 4

4. Sampling and Analytical Procedures

..................................................................................................................... 5

4.1. Test Methods .............................................

............................................................... ............................................................... .......... 5

4.2.  Gas Velocity and Volumetric Flow Rate ...................

............................................................... .............................................. 5

4.3.  Moisture Content ........................................

............................................................... ............................................................... ...... 5

4.4.  Oxygen and Carbon Dioxide Concentration .................

............................................................... ........................................ 5

4.5.  HCl Emissions ...........................................

............................................................... ............................................................... ......... 5

5. Summary of Test Results

............................................................................................................................... ............. 6

5.1.  Test Results ............................................

............................................................... ............................................................... ............. 6

6. Quality Assurance/Quality Control

........................................................................................................................ 7

6.1.  Equipment Calibration ...................................

............................................................... ............................................................... 7

6.2.  Leak Checks .............................................

............................................................... ............................................................... ........... 7



### LIST OF TABLES

1  Summary of Source Emission Test Results



### LIST OF APPENDICES

A  Facility Operating Data

B  Schematic of the Test Location

C  Field Data and Calculations D  Equipment Calibration Data E  Enthalpy Analytical, Inc. Test ReportMAIN KILN EXHAUST SOURCE EMISSION TESTING

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### 1. INTRODUCTION AND BACKGROUND

O’Brien & Gere was retaine d by Lafarge Building Materials, Inc. (Lafarge) to conduct source emission testing on the main kiln exhaust at the Lafarge facility located in Ravena , New York. The objective of the test program was to satisfy the hydrogen chloride (HCl) Information Collection Request (ICR) issued by the United States Environmental Protection Agency (USE PA) on February 3, 2010.

Messrs. Brian Garrett and Mi ke Salvagno of O’Brien

& Gere and Mr. Clint Thrasher of Enthalpy Analytical, Inc. performed the field test program. Mr. Paul Rappleyea was p resent to monitor process

conditions and colle ct facility data.

The remaining sections of this report include a summary of the source test program, process description, sampling methods used, QA/QC procedures followed for th e testing equipment, and a summary of the test results.



### 1.1. EMISSIONS TESTING PROGRAM

PARTICIPANTS

Facility

Name:      Lafarge Building Materials,

Inc.

Site Address:    1916 Route 9W
Ravena, NY 12143

Contact:    Paul Rappleyea

Telephone number:  (518) 756‐5028 Source Testing Companies

Name:      O’Brien & Gere

Address:    5000 Brittonfield Parkway East Syracuse, New York

13057

Contact:    David Ostaszewski

Telephone number:  (315) 437‐6100

Name:      Enthalpy Analytical, Inc.

Address:    2202 Ellis Road Durham, North Carolina

27703

Contact:    Bryan Tyler

Telephone number:  (919) 850‐4392MAIN KILN EXHAUST SOURCE EMISSION TESTING

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### 2. SOURCE DESCRIPTION AND PROCESS OPERATING DATA

This section provides a de scription of the Portland Cement kilns tested, as well as operating requirements and paramet ers maintained during testing.



### 2.1. PROCESS DESCRIPTION

The Lafarge Ravena Facil ity is dedicated for portland cement manufactur ing and sales. Lafarge operates two rotary kilns c apable of firing coal and petroleum coke. Both kil ns are exhausted into an electrostatic precipitator for particulate emissions control before being exha usted through a common stack to the atmosphere.



### 2.2. SAMPLING LOCATION DESCRIPTION

The kilns exhaust to atm osphere through a common circular stack approximately 260 inches in diameter. Two test ports, spaced 180  apart are located 122 feet (approxim ately 5.6 duct diameters)

downstream of the nearest flow disturbance and 186 feet (approximately 8.6 duct diameters) upstream of the stack exha ust point. These ports

were used to conduct the volumetric flow rate monitoring. The HCl monitoring was not conducted at this location due to the length of sample line required to access this location. The long sample line length resulted in di fficulty achieving method sample recovery QA criteria. Therefore, HCl sampling was conducted in a dedicated breaching to

the kiln exhaust stack. Sche matics of test locations are presented in Appendix B.



### 2.3. OPERATING PARAMETERS

The testing was conducte d while one kiln was online firing a mixture of coal and petroleum coke and operated at greater than 90 percent load. Kiln operations data was collected by facility personnel.

These data included clinke r production rate, slurry feed rate (liter/min), and fuel feed rate (ton/hr). These facility process data are presented in Appendix A of this test report.MAIN KILN EXHAUST SOURCE EMISSION TESTING

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### 3. SUMMARY OF TEST PROGRAM

This section provides a summary of the testing scope of work conducted on the main kiln exhaust at the Lafarge facility.



### 3.1. TEST PROGRAM SUMMARY

Source emission testing was conducted to evaluate

emissions of HCl from the main kiln exhaust located at the Lafarge facility. Testing was completed on March 12, 2010 by O’Brien & Gere (volumetric flow rate measurements) and Ent halpy Analytical, Inc. (HCl FTIR monitoring) personnel.

Testing was conducted in t riplicate during normal process operating conditions as maintained by facility personnel. Test du rations were 60 minutes. As previously mentioned in Section 2.3, one of the

two kilns was online durin g the test program. The kiln fired a mixture of coal and petroleum coke during the testing and was operated at greater than 90 percent capacity. As previously noted, HCl testing could not be completed at the stack location due to the length of sample line required to tr ansport the sample from the test port on the p latform to the FTIR

instrument. The extended s ample line length made it difficult to consistently meet method spike sample recovery criteria. T herefore, it was decided on‐site to obtain HCl samples in the dedicated breaching to the kiln stac k which could be reached with a much shorter sample line. To evaluate potential pollutant stratifi cation at this location, an oxygen stratification check was conducted across

the ductwork. The results o f this check indicated that there was no signific ant stratification in the ductwork and the location was acceptable for HCl sampling. Note tha t oxygen data collected at this

location were used to correc t HCl concentrations to

7 % O 2 . Results of this test ing can be found in Appendix C.MAIN KILN EXHAUST SOURCE EMISSION TESTING

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### 4. SAMPLING AND ANALYTICAL PROCEDURES

This section provides a description of the test

methods utilized durin g the RATA program.



### 4.1. TEST METHODS

Emissions testing was conducted using USEPA Reference Methods (RM) de scribed in Title 40 CFR Part 60, Appendix A.

RM 1:  Sample and velocity traverses for stationary sources

RM 2:  Determination of stack gas velocity and volumetric flow rate (Type‐S pitot tube)

RM 3/3A:  Determination of oxygen and

carbon dioxide concentrations in emissions from stationary sources

RM 4:  Determination of moisture content in stack gases

RM 321:  Determination of HCl emissions from stationary sources – FTIR Analyzer Procedure



### 4.2. GAS VELOCITY AND VOLUMETRIC FLOW

RATE

The gas velocity was det ermined using velocity pressure data measured using a stainless steel Type‐S pitot tube and manometer across the diameter of the ductwork. The gas stream temperature was moni tored using a Type K thermocouple attached to th e pitot tube. Note that there are only two test po rts located 180 degrees apart in the same plane available for reference method sampling on the sta ck platform. Therefore, velocity and temperature traverses were taken

across the duct in two directions, us ing the existing ports. Note that this port layout and volumetric flow rate procedure has been approved by New York State Department of Envir onmental Conservation (NYSDEC) in the past for p revious compliance test programs. USEPA RMs 1 and 2 were followed to establish the equal a reas to be measured in identifying the gas veloci ty and volumetric flow

rate. 

### 4.3. MOISTURE CONTENT

Moisture content was qu antified utilizing procedures identified in USEPA RM 4. A sample of gas was continuously collected using a dry gas meter stack sampling syste m condensed in a series of impingers. The moisture content of the gas was measured as a change in the volume of the water collected in each impin ger solution and the increased weight of the desiccant during the sampling period.



### 4.4. OXYGEN AND CARBON DIOXIDE

CONCENTRATION

Oxygen concentrations at the HCl sample location in

the stack breachin g were determined in accordance with USEPA RM 3A using a California Analytical Instruments Model 600 paramagnetic analyzer. A continuous gas sample was extracted from the exhaust stack through a sintered filter, stainless steel probe, heated Teflon line and through a conditioning system used to remove moisture from the gas stream. All materi al that came in contact with the sample was constr ucted of either stainless steel, glass, or Teflon.

The reference method an alyzer outputs were monitored using a laptop computer and PCMCIA card and recorded by a data acquisition system (DAS). The DAS reported oxygen data as 1‐minute averages for each test run. Oxygen emissions data reported by the DAS was c orrected for system zero and span bias. Oxygen and carbon dioxide

concentrations at the stack location were determined in conjunction with each test run in accordance with USEPA RM 3 procedures using an Orsat apparatus.



### 4.5. HCL EMISSIONS

Concentrations of HCl were evaluated in accordance with USEPA RM 321 procedures using an on‐site FTIR analyzer. Sample gas was extracted through a probe assembly and heat‐ traced line, through a sample gas dryer, and into the absorption cell of the FTIR spectrometer. The heat traced line was maintained at approximat ely 375Deg. F. The FTIR

instrument was a MIDAC (Series I‐1301) medium‐

resolution Michelson int erferometer spectrometer. Further details of the FTIR sampling and analytical instrumentation can be found in Appendix E.MAIN KILN EXHAUST SOURCE EMISSION TESTING

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### 5. SUMMARY OF TEST RESULTS

A summary of the test resul ts can be found in Table 1. Supporting field data a nd calculations can be found in Appendix C. FTIR HCl analytical results can be found in Appendix E. A brief discussion of the test results is presented below.



### 5.1. TEST RESULTS

A review of Table 1 indicates that HCl concentrations on a wet basis ranged from approximately 20.1 ppm t o approximately 25.2 ppm, averaging approx imately 22.5 ppm. HCl concentrations corrected to 7% percent oxygen ranged from approximatel y 23.4 to approximately 29.1 ppm, averaging approx imately 26.2 ppm.

Except as noted, there were no operational or testing problems that impa cted the test results and

all test data is believed to be representative of the

emissions encountered dur ing the test program.MAIN KILN EXHAUST SOURCE EMISSION TESTING

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### 6. QUALITY ASSURANCE/QUALITY CONTROL

QA/QC were based on the recommended QA/QC procedures of the various sampling and analytical

methods that were used for the  source test program. This section su mmarizes the pertinent QA/QC procedures that w ere employed during the emissions testing prog ram. Field equipment calibration data can be found in Appendix D and in the Enthalpy Analytical Rep ort located in Appendix

E.



### 6.1. EQUIPMENT CALIBRATION

Analyzers, dry gas meters, thermocouples, and pitot

tubes were calibrated i n accordance with the procedures outlined in t he corresponding USEPA test methods and/or the USEPA document entitled Quality Assurance Handb ook for Air Pollution Measurement Systems: V olume III ‐ Stationary Source Specific Methods (EPA 600/R‐94/038c).

Continuous emission monit oring analyzer response

time tests were conducted on each anal yzer and the entire measurement system , as applicable. Each analyzer and the entire instrume nt measurement system were challenged with EPA Protocol No. 1 gas standards (zero and mid gas) in accordance with procedures specified in each respective test method. The calibration gases were introduced to the sampling system at the sample probe to expose

the calibration standa rds to as much of the sampling system as possible. O 2 concentrations

were bias corrected in acco rdance with USEPA RM 7E procedures.

Protocol calibration standards were prepared in accordance with USEPA Traceability Protocol for Assay and Certification of Gaseous Calibration Standards. The accuracy of these gases were +/‐2%

or better. For those concentrations that exceed the concentration range for co mmercially available EPA Protocol standards, the highest analytical grade commercially available ( i.e. master blend) standards were used.  Cop ies of the calibration

certificates are included in Appendix D of this final

source test report.



### 6.2. LEAK CHECKS

Pitot tube leak checks were conducted in

accordance with USEPA RM 2. Leak checks were

conducted on the moisture sampling trains prior to and following each test run in accordance with

USEPA RM 4.TABLES

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### Table 1
Summary of Source Testing Results

Main Kiln Exhaust
Lafarge Ravena Plant

Ravena, New York

Run Identification Run 1 Run 2 Run 3 Average

Run Date 3/12/10 3/12/10 3/12/10
Start/Stop Time 1036-1136 1201-1301 1403-1503

Exhaust Gas Conditions
Temperature (deg. F) 396.0 401.2 401.8 399.7

Moisture (volume %) 26.4 25.2 24.7 25.4
Oxygen (dry volume %) 10.4 10.3 10.4 10.4
Carbon Dioxide (dry volume %) 18.6 18.3 17.9 18.3

Volumetric Flow Rate

acfm 577,110 575,860 590,980 581,317

dscfm 261,760 263,980 272,530 266,090

HCl Concentrations
ppm, wet 22.2 20.1 25.2 22.5

ppm, dry basis @7% O2 26.2 23.4 29.1 26.2

O'Brien & Gere I:\Lafarge.14198\45892.Source

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‐ D\HCl Table.xlsx\Summary TableAPPENDIX A │ FACILITY OPERATING DATA

360° Engineering and Project Delivery SolutionsAPPENDIX B │ SCHEMATIC OF THE TEST LOCATION

360° Engineering and Project Delivery SolutionsAPPENDIX C │ FIELD DATA AND CALCULATIONS

360° Engineering and Project Delivery SolutionsAPPENDIX D │ EQUIPMENT CALIBRATION DATA

360° Engineering and Project Delivery SolutionsAPPENDIX E │ ENTHALPY ANALYTICAL INC. REPORT

360° Engineering and Project Delivery Solutions