FINAL REPORT

HYDROCHLORIC ACID; HYD_ROFLUOR!C

ACID AND P.•.RT!CUL.&TE EMISSION TESTING

TUNNEL KILN SCRUBBER CUSHWA PLANT

REDLAND BRICK,

I•NC WILLIAMSPORT MARYLAND
PROJECT 1296 JUNE 2, 2006

PREPARED BY ALEX KEFFALAS PROJECT ENGINEER

BLUE MOUNTAIN

ENVIRONMENTAL MANAGEMENT

CORPORATION 1191 PITTSBURGH

ROAD VALENCIA, PENNSYLVANIA

16059TABLE OF CONTENTS 1.0 EXECUTIVE

SUMMARY

................................................... 1 2.0 SCOPE

AND OBJECTIVES

................................................................................. 2 3.0 PROCESS

DESCRIPTION

................................................................................... 4 4.0 PROCEDURES

..................................................................................................... 5 4.1 Field Work 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.1.6 4.1.7 4.1.8 Field Data Sheets

.......................................................................... 5 Emission Testing

Station

and Traverse

Locations 5 Determination of Gas Flow and Gas Temperature 5 Determination of Carbon

Dioxide

and Oxygen 5 Determination of Moisture

Content

.............................................. 6 Determination of Particulate

Emissions

...................................... 6 Determination of Visible

Emissions

............................................ 6 Determination of Hydrochloric

Acid and •Hydrogen

Fluoride Emissions -. .......................................................... 6 4.1.9 Sample

Recovery

Procedure

............................................... 6 4.24.34.44.5 Laboratory

Analyses

................................................................................... 7 Calculations

.............................................................................................. 7 Field Equipment

Calibrations

.................................................................. 7 Process Data

............................................................................................ 7 5.0 SUMMARY

OF RESULTS

.................................................................................... 8 TABLES Table 1 Table 2 Table 3 Table 4 FIGURES Figure 1 Figure 2

Emission

Summary Tunnel Kiln Scrubber

Loading

Summary Tunnel Kiln Scrubber

Emissions

Summary Tunnel Kiln Scrubber

Capture

Efficiency
Inlet Sampling

Location

and Traverse

Points Outlet Sampling

Location

and Traverse

Points APPENDICES Appendix A Appendix B Appendix C Appendix D Appendix E

Field Data Sheets Analytical Data Calculations Field Equipment

Calibrations Process Data1.0 EXECUTIVE

SUMMARY Redland Brick, Inc. (Redland

Brick) contracted

Blue Mountain

Environmental

Management Corporation (Blue Mountain)

to conduct

a hydrochloric

acid (HC1) and hydrofluoric

acid (HF) loading, emissions

and capture efficiency

evaluation

and a particulate

emissions

evaluation

of the Cushwa Plant Tunnel Kiln Scrubber

(Hellmich

dry limestone

absorber)

located in Williamsport, Maryland. Sampling

and analyses

were conducted

using the principles

of U.S. Environmental Protection Agency

(EPA) methods

specified

in 40 CFR, Part 60, Appendix

A. The Tunnel Kiln operated

at a push rate of 32.6 cars per day, during the testing. Table 1 presents summary, of the HCI. HF and nnrtimd•t•

•m;•;

I;

1.• a

TABLE

1 EMISSIONS SUMMARY
Parameter Particulate Emissions: gr/dscf Ib/hr lb/ton HCI Emissions: ppm lbPar lb/ton Caoture Efficiency,

% HF Emissions: ppm tbhtr lb/ton Capture Efficiency,

% Run 10.009 1.68 0.11
2.2 0.28 0.018 70.61.2 0.08 0.005 99.3 Run 2 Run3 0.017 0.021 3.46 4.26 0.22 0.27. 2.3 2.1 0.31 0.28 0.020 0.018 70.4 65.31.6 0.12! 0.001 99.13 1.1 0.08 0.005 99.3 Average0,01• 3.13 0.2£
2.2 0.29 0.018 68.[

0.0• 0.00• 99_•2.0 SCOPE

AND OBJECTIVES The scope of this project was to determine

HC1 and HF loading,

emissions

and capture efficiency and particulate

emissions

from the Cushwa

Plant Tunnel Kiln Scrubber

located at the Williamsport Plant using approved

reference-sampling

methods.

The results of the test are intended to determine

MACT compliance

and maintain

compliance

with Maryland

Department of the Environment

(MDOE)

regulations.

.... The following

parameters

were determined

for each of three test runs:

• Gas Flow

• Gas Temperature

• Gas Analysis

. Gas Moisture

• Sample Gas Volume

• Isokinetie

Ratio

• HC1 Loading

& Emissions

• I-IF Loading

& Emissions

• Particulate

Emissions

• Scrubber

Efficiency

• Scrubber

PreSsure

Drop

o Visible Emissions ClSh and O• % by volume % by volume dscf %ppm, lb/hr and lb/ton ppm, lbPar and lb/ton grains/dscf, lb/hr and lb/ton % HC1 and I-IF Removal inches of water % opaque The field-sampling

program

was performed

on May 10-11, 2006. The Blue Mountain

test personnel consisted

of Messrs.

Heath Christy,

Alex Keffalas

and Doug Leighty.

Mr. Barry Miller served as the plant liaison for this test program

and conducted

the visible emission observations.

acfin dscfm CO: ozdscf ppm lb/hr lb/ton gr/dscf actual cubic feet per minute dry standard

cubic feet per minute degrees Fahrenheit carbon dioxide oxygen dry standard

cubic feet parts per million pounds per hour pounds per ton grains per dry standard

cubic feetBlue Mountain

Contact:

Alex Keffalas Blue Mountain

Environmental

Management

Corporation 1191 Pittsburgh

Road Valencia, Pennsylvania

16059 Telephone: (724) 898-4500 Facsimile: (724) 898-2908 Redland Brick Contact:

Barry Miller Redland Briek• Inc. PO Box 160 15718 Clear Spring Road Williamsport, Maryland

21795 Telephone: (301) 223-7700 Faesirnile: (301) 223-6675 Laboratory Contact:

.Nancy Kotsko Air Quality Services,

Inc. 4527 Clairton

Boulevard Pittsburgh, PA 15236 Telephone: (412) 881-56303.0 PROCESS

DESCRIPTION The Cushwa

Plant manufactures

molded bricks. Shale is minedon-site

and is crushed,

ground, mixed with water, formed in sanded molds, dried to remove moisture,

stacked onto kiln cars which are transferred

into a Lingl natural gas•fired

tunnel kiln and heated to a temperature

of approximately 2000 degrees Fahrenheit.

The final product

is allowed

to cool and then is packaged. The Lingl Tunnel Kiln has a maximum

push rate of 34 cars per day. Exhaust

gases from the Tunnel Kiln are exhausted

through the Tunnel Kiln Scrubber.

44.0 PROCEDURES 4.1 FIELD WORK 4.1.1 Field Data Sheets Copies of all field data sheets are included

in Appendix

A. 4.1.2 Emission

Testing

Stations

and Traverse

Locations The inlet sampling

station is located in the duct between

the exit end of the kiln and the inlet to the Tunnel Kiln Scrubber.

The diameter

of the duet is 39 inches. The nearest downstream disturbance is a bend in the duet, which is approximately

36 inches or 0.9 diameters

from the test ports. The nearest upstream

disturbance

is 108 inches or 2.8 diameters

from the test ports. EPA Method 1-Sample

and Velocity

Traverses

For Stationary

Sources was used to determine

the number and location

of the traverse

points. Twenty-four

(24) sampling

points were used, twelve (12) at each of the two test ports that are located 90 degrees to center. The sampling

points were located from the inner wall of the stack as follows based on a 39 inch intemal stack diameter: 1.0, 2.6, 4.6, 6.9, 9.8, 13.9, 25.1, 29.3, 32.1, 34.4, 36.4 and 38.0 inches. A drawing

of the duet sampling location

and a table of the traverse points is included

in Figure 1. The outlet sampling

station is located in the Tunnel Kiln Scrubber

exhaust stack. The diameter of the stack is 44 inches. The nearest downstream

disturbance

is the stack exit, which is 75 inches or 1.7 diameters

from the test ports. The nearest upstream

disturbance

is 50 feet or 13.6 diameters from the test ports. EPA Method

1 was used to determine

the number and location

of the traverse

points. Twelve

(12) sampling

points were used, six (6) at each of the two test ports that are located 90 degrees to center. The sampling

points were located from the inner wall of the stack as follows based on a 44 inch internal stack diameter:

1.9, 6.4, 13.0, 31.0, 37.6 and 42.1 inches. A drawing

of the stack sampling

location

and a table of the traverse

points is included

in Figure 2. 4.1.3 Determination

of Gas Flow and Gas temperature The gas flow rate and temperature

profiles

for the gas stream were measured

by conducting simultaneous velocity

and temperature

traverses

concurrently

with each emission

sampling

run. Gas velocity

head was measured

with a calibrated

"S"-type

pitot tube that was connected

to an inclined manometer.

A chrome-alumel

thermocouple

attached

to a digital indicator

was used to measure the gas temperature

at each of the traverse

points. The gas flow and gas temperature measurements followed

the principles

of EPA Method

2- Determination

of Stack Gas Velocity and Volumetric

Flow Rate (Type S Pitot Tube). 4.1.4 Determination

of Carbon

Dioxide

and Oxygen A Fyrite analyzer

was used to determine

the molecular

weight of the inlet and outlet flue gas for the measurement

of gas flow during each sampling

run. Three grab samples

were collected

ateach sampling

location

during each sample run using the principles

of EPA Method

3-Gas Analysis For The Determination

Of Dry Molecular

Weight.

The following

parameters

were measured: percent by volume of carbon dioxide

(CO2), percent by volume

(02) and percent nitrogen (N2) was determined

by difference. 4.1.5 Determination

of Moisture

Content Moisture sampling

was conducted

concurrently

with each emission

sampling

rtm using the principles presented

in EPA Method

4 -Determination

of Moisture

Content

in Stack Gases concurrently with the HCI and I-IF loading and emission

sampling.

Parameters

evaluated

to determine the gas stream moisture

content were: sample gas volume,

sample gas temperata•re• sample gas pressure,

impinger

moisture

gain, and silica gel moisture

gain. 4.1.6 Determination

of Particulate

Emissions EPA Method

5-Determination

of Particulate

Emissions

from Stationary

Sources was used in this test program.

The EPA Method

5 sampling

train was incorporated

with the outlet sampling station sampling

train that also collected

HC1 and HF emissions.

Particulate

matter was withdrawn isokinetically

from the gas stream and collected

in a nozzle, probe and filter. The particulate Sample catches were recovered.

The average of three sampling

runs constituted

the test. 4.1.7 Determination

of Visible

Emissions A certified

visible emission

observer

observed

the opacity of the stack exhaust gases. A copy of his certification

is included

in Appendix

D. EPA Method

9-Visual

Determination

of the Opacity of Emissions

from Stationary

Sources

was used. One twenty-minute

observation

was conducted during Run 2 of the particulate,

HC1 and HF emission

testing. 4.1.8 Determination

of Hydrochloric

Acid and Hydrofluoric

Acid Loading

and Emissions EPA Method

26A-Determin•ition

of Hydrogen

Halide and Halogen

Emissions

from Stationary Sources was used in this test program.

At the inlet and outlet HC1 and HF in particulate

and gaseous form were withdrawn

isokinetically

from the gas stream and collected

using a glass-lined probe, glass nozzle and filter. A series of glass impingers

containing

a 0.1 normal sulfuric acid solution and silica gel collected

HC1, I-IF and water vapor. Chlorine

was not analyzed

for this test program

and therefore,

impingers

containing

a sodium hydroxide

solution

were not included. The average

of three 60-minute

sampling

runs constituted

the test. 4.1.9 Sample

Recovery

Procedure Recovery of samples

was conducted

on-site in accordance

with EPA Method

5 and 26A procedures.

64.2 LABORATORY

ANALYSES Blue Mountain

conducted

all particulate

gravimetric

analyses

of the particulate

catches in accordance with EPA Method

5 procedures.

Air Quality Services,

Inc. conducted

the HC1 and HF analysis

according

to EPA Method

26A. Appendix B. 4.3 CALCULATIONS Copies of the Laboratory

Reports

are contained

in

Emission calculations

were completed

using a computer

spreadsheet

format.

The results of each pertinent parameter

were detailed

on the spreadsheet

for each sampling

run and are contained

in Appendix C. A sampIe calculation

for Run 1 is included. 4.4 FIELD EQUIPMENT

CALIBRATIONS The following

field equipment

calibration

data is included

in Appendix

D:

• Nozzle;

• Dry Gas Meter and Orifice;
* Thermocouple;

• Pitot Tube; and

o Visible Emission

Certificate. 4.5 PROCESS

DATA Documentation of process production

during the emission

testing is included

in Appendix

E.

75.0 SUMMARY

OF RESULTS Table 1 presents

the HCland

HF Loading

Summary. The HC1 loading concentration

ranged from 7.5 ppm to 9.4 ppm and the average concentration was 8.3 ppm. The HC1 loading ranged from 0.80 lb/hr to 1.04 lb/hr and the average loading rate was 0.93 lb/hr. The HCI loading ranged from 0.051 lb/ton to 0.067 lb/ton of brick produced

and the average

loading rate was 0.059 lb/ton of brick produced. The I-IF loading concentration

ranged from 174.4 ppm to 203.2 ppm and the average concentration was 192.5 ppm. The HF loading ranged from 11.08 lb/hr to 12.37 lb/hr and the average loading rate was 11.73 lb/hr. The I-• loading ranged from 0.709 lb/ton to 0.792 lb/ton of brick produced

and the average

loading rate was 0.751 lb/ton of brick produced. Table 2 presents

the particulate,

HC1 and HF Emissions

Summary. The particulate

emission

concentration

ranged from 0.009 gr/dscf to 0.021 gr/dscf and the average concentration

was 0.016 gr/dscf..

The particulate

emissions

ranged from 1.68 lb/hr to 4.26 lb/hr and the average

emission

rate was 3.13 lb/hr. The particulate

emissions

ranged from 0.11 lb/ton to 0.27 Ib/ton of brick produced

and the average

emissions

rate was 0.20 lb/ton of brick produced. The HC1 emission

concentration

ranged from 2.1 ppm to 2.3 ppm and the average concentration was 2.2 ppm. The HC1 emissions

ranged from 0.28 lb/hr to 0.31 lbPar and the average

emissions rate was 0.29 lb/hr. The HC1 emissions

ranged from 0.018 lb/ton to 0.020 lb/ton of brick produced and the average

emissions

rate was 0.018 lb/ton of brick produced. The HF emission

concentration

ranged from 1.1 ppm to 1.6 ppm and the average concentration was 1.3 ppm. The HF emissions

ranged from 0.08 lb/hr to 0.12 lbPar and the average emissions rate was 0.09 lb/hr. The I-• emissions

ranged from 0.005 lb/ton to 0.008 Ib/ton of brick produced and the average

emissions

rate was 0.006 lbTton of brick produced. There were no visible emissions. Table 3 presents

the Capture

Efficiency

Summary.

The HCI capture efficiency

ranged from 65.3 to 70.6 percent and the average was 68.8 percent.

The HF capture efficiency

ranged from 99.0 to 99.3 percent and the average

was 99.2 percent.TABLE 2 REDLAND BRICK CUSHWA PLANT TUNNEL KILN SCRUBBER MAY 10-11, 2006 BLUE MOUNTAIN

PROJECT

1296 LOADING SUMMARY
Parameter Gas flow, acfm Gas flow, dsefm [Gas temperature,

°F Gas moisture,

% by volume Isokinetie ratio, % HCI Loading: ppm Ib/hr lb/tonLoading: ppm lb/hr lb/ton Run 1 31399 20391 250.2 10.0 102.98.1 0.93 0.060 174.4 11.08 0.709 Run 2 30045 19545 242.5 10.3 100.59.4 1.04 0.067 203.2 12.37 0.792 Run 3 28825 18847 243.19.8 103.57.5 0.80 0.051 199.9 11.74 0.751 Average 30090 19594 245.3 10.0 102.38.3 0.93 0,059 192.5 11.73 0.751TABLE 3 REDLAND BRICK CUSHWA PLANT TUNNEL KILN SCRUBBER

STACK MAY t0-11, 2006 BLUE MOUNTAIN

PROJECT

1296 EMISSIONS SUMMARY Parameter Gas flow, acfm Gas flow, dscffn Gas temperature,

°F Gas moisture,

% by volume Isokinetie ratio, % Particulate Emissions: •r/dscf lb/hr lb/ton BCI Emissions: ppm lb/hr lb/ton HF Emissions: ppm lb/hr lb/ton Run 1 32684 21713 245.39.6 100.3 0.009 1.68 0.11 2.2 0.28 0.0181.2 0.08 0.005 Run2356811 23737 243.89.2 101.9 0.017 3.46 0.222.3 0.31 0.0201.1 0.08 0.005

Run 3 34572 23643 226.98.9 98.8 0.021 4.26 0.272.1 0.28 0.0181.6 0.12 0.008 Average 34312 23031 238.7!9.2 100• 0.016 3.13 0.202.2 0.29 0.0181.3 0.09 0.006TABLE 4 REDLAND BRICK CUSHWA PLANT TUNNEL KILN SCRUBBER

STACK MAY 10-11, 2006 BLUE MOUNTAIN

PROJECT

1296 CAPTURE EFFICIENCY

SUMMARY Parameter [-ICI Loading,

lb/hr: HCI Emissions,

lb/hr: I-IC1 Capture

Efficiency,

% HF Loading,

lb/hr: I-IF Emissions,

lb/hr: HI." Capture

Efficiency,

% Run 10.935 0.275 70.6 11.084 0.079 99.3 Run 21.045 0.309 70.4 12.373 0.084 99.3 Run 30.804 0.279 65.3 11.739 0.120 99.0 Average0.928 0.28• 68.8 11.732 0'.094 99.2FIGURE 1 Redland Brick Tunnel Kiln

Scrubber

Inlet Cushwa Plant,

Williamsport, Maryland

Bend to Scrubber i----] A QB • Flow Bend From,i

Traverse Points 123456.789101112

Innex Distance (inches) 1.02.64.66.99.8 13.9 25.1 29.3 32.1 34.4 36.4 38.0FIGURE 2 Redland Brick Tunnel Kiln

Scrubber

Stack Cushwa Plant,

Williamsport, Maryland

Flow 50'

Traverse Points 123456

Inner Distance (Inches) 1.96.4 13.0 31.0 37.6 42.1

Fan