Lafarge Building Materials, Inc.

Ravena, New York

March 30, 2010

Main Kiln Exhaust Source Emission Testing

SOURCE EMISSION TEST REPORT
SOURCE EMISSION TEST REPORT

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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

1 FINAL:  March 30, 2010

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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 Program 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 Report 
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1.  INTRODUCTION AND BACKGROUND

O’Brien & Gere was retained 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 (USEPA) on February 3, 2010.  

Messrs. Brian Garrett and Mike Salvagno of O’Brien 

& Gere and Mr. Clint Thrasher of Enthalpy 

Analytical, Inc. performed the field test program. 

Mr. Paul Rappleyea was present to monitor process 

conditions and collect 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 the 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) 850‐4392
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2.  SOURCE DESCRIPTION AND PROCESS OPERATING DATA

This section provides a description of the Portland 

Cement kilns tested, as well as operating 

requirements and parameters maintained during 

testing. 

2.1.  PROCESS DESCRIPTION

The Lafarge Ravena Facility is dedicated for 

portland cement manufacturing and sales. Lafarge 

operates two rotary kilns capable of firing coal and 

petroleum coke. Both kilns are exhausted into an 

electrostatic precipitator for particulate emissions 

control before being exhausted through a common 

stack to the atmosphere. 

2.2.  SAMPLING LOCATION DESCRIPTION

The kilns exhaust to atmosphere through a common 

circular stack approximately 260 inches in 

diameter. Two test ports, spaced 180 apart are 

located 122 feet (approximately 5.6 duct diameters) 

downstream of the nearest flow disturbance and 

186 feet (approximately 8.6 duct diameters) 

upstream of the stack exhaust 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 difficulty achieving method 

sample recovery QA criteria. Therefore, HCl 

sampling was conducted in a dedicated breaching to 

the kiln exhaust stack. Schematics of test locations 

are presented in Appendix B. 

2.3.  OPERATING PARAMETERS

The testing was conducted 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 clinker 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.
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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 Enthalpy Analytical, Inc. 

(HCl FTIR monitoring) personnel.  

Testing was conducted in triplicate during normal 

process operating conditions as maintained by 

facility personnel. Test durations were 60 minutes. 

As previously mentioned in Section 2.3, one of the 

two kilns was online during 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 transport the sample from 

the test port on the platform to the FTIR 

instrument. The extended sample line length made 

it difficult to consistently meet method spike 

sample recovery criteria. Therefore, it was decided 

on‐site to obtain HCl samples in the dedicated 

breaching to the kiln stack which could be reached 

with a much shorter sample line. To evaluate 

potential pollutant stratification at this location, an 

oxygen stratification check was conducted across 

the ductwork. The results of this check indicated 

that there was no significant stratification in the 

ductwork and the location was acceptable for HCl 

sampling. Note that oxygen data collected at this 

location were used to correct HCl concentrations to 

7 % O2. Results of this testing can be found in 

Appendix C.  
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4.  SAMPLING AND ANALYTICAL PROCEDURES

This section provides a description of the test 

methods utilized during the RATA program. 

4.1. TEST METHODS

Emissions testing was conducted using USEPA 

Reference Methods (RM) described 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 determined 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 monitored using a Type K 

thermocouple attached to the pitot tube. Note that 

there are only two test ports located 180 degrees 

apart in the same plane available for reference 

method sampling on the stack platform. Therefore, 

velocity and temperature traverses were taken 

across the duct in two directions, using the existing 

ports. Note that this port layout and volumetric flow 

rate procedure has been approved by New York 

State Department of Environmental Conservation 

(NYSDEC) in the past for previous compliance test 

programs. USEPA RMs 1 and 2 were followed to 

establish the equal areas to be measured in 

identifying the gas velocity and volumetric flow 

rate.  

4.3.  MOISTURE CONTENT

Moisture content was quantified utilizing 

procedures identified in USEPA RM 4. A sample of 

gas was continuously collected using a dry gas 

meter stack sampling system 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 impinger 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 breaching 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 material that came in contact 

with the sample was constructed of either stainless 

steel, glass, or Teflon. 

The reference method analyzer 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 corrected 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 approximately 375Deg. F. The FTIR 

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

resolution Michelson interferometer spectrometer. 

Further details of the FTIR sampling and analytical 

instrumentation can be found in Appendix E.

   
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5.  SUMMARY OF TEST RESULTS

A summary of the test results can be found in Table 

1. Supporting field data and 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 to approximately 25.2 

ppm, averaging approximately 22.5 ppm. HCl 

concentrations corrected to 7% percent oxygen 

ranged from approximately 23.4 to approximately 

29.1 ppm, averaging approximately 26.2 ppm.  

Except as noted, there were no operational or 

testing problems that impacted the test results and 

all test data is believed to be representative of the 

emissions encountered during the test program. 
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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 summarizes the pertinent 

QA/QC procedures that were employed during the 

emissions testing program. Field equipment 

calibration data can be found in Appendix D and in 

the Enthalpy Analytical Report located in Appendix 

E. 

6.1.  EQUIPMENT CALIBRATION

Analyzers, dry gas meters, thermocouples, and pitot 

tubes were calibrated in accordance with the 

procedures outlined in the corresponding USEPA 

test methods and/or the USEPA document entitled 

Quality Assurance Handbook for Air Pollution 

Measurement Systems: Volume III ‐ Stationary 

Source Specific Methods (EPA 600/R‐94/038c).  

Continuous emission monitoring analyzer response 

time tests were conducted on each analyzer and the 

entire measurement system, as applicable. Each 

analyzer and the entire instrument 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 standards to as much of the 

sampling system as possible. O2 concentrations 

were bias corrected in accordance 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 commercially available EPA 

Protocol standards, the highest analytical grade 

commercially available (i.e. master blend) 

standards were used.  Copies 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

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APPENDIX A │FACILITY OPERATING DATA

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APPENDIX B │SCHEMATIC OF THE TEST LOCATION

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APPENDIX C │FIELD DATA AND CALCULATIONS

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APPENDIX D │EQUIPMENT CALIBRATION DATA

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APPENDIX E │ ENTHALPY ANALYTICAL INC. REPORT

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