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 16059 
TABLE 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 

4.2 

4.3 

4.4 

4.5 

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 Data 
1.0 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 1 

0.009 

1.68 

0.11 

2.2 

0.28 

0.018 

70.6 

1.2 

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 65.3 

1.6 

0.12! 

0.001 

99.13 

1.1 

0.08 

0.005 

99.3 

Average 

0,01• 

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: 

oz 

dscf 

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 feet 
Blue 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) 881-5630 
3.0 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. 

4 
4.0 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 at 
each 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. 

6 
4.2 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. 

7 
5.0 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/ton 

Loading: 

ppm 

lb/hr 

lb/ton 

Run 1 

31399 

20391 

250.2 

10.0 

102.9 

8.1 

0.93 

0.060 

174.4 

11.08 

0.709 

Run 2 

30045 

19545 

242.5 

10.3 

100.5 

9.4 

1.04 

0.067 

203.2 

12.37 

0.792 

Run 3 

28825 

18847 

243.1 

9.8 

103.5 

7.5 

0.80 

0.051 

199.9 

11.74 

0.751 

Average 

30090 

19594 

245.3 

10.0 

102.3 

8.3 

0.93 

0,059 

192.5 

11.73 

0.751 
TABLE 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 

245.3 

9.6 

100.3 

0.009 

1.68 

0.11 

2.2 

0.28 

0.018 

1.2 

0.08 

0.005 

Run2 

356811 

23737 

243.8 

9.2 

101.9 

0.017 

3.46 

0.22 

2.3 

0.31 

0.020 

1.1 

0.08 

0.005 

Run 3 

34572 

23643 

226.9 

8.9 

98.8 

0.021 

4.26 

0.27 

2.1 

0.28 

0.018 

1.6 

0.12 

0.008 

Average 

34312 

23031 

238.7! 

9.2 

100• 

0.016 

3.13 

0.20 

2.2 

0.29 

0.018 

1.3 

0.09 

0.006 
TABLE 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 1 

0.935 

0.275 

70.6 

11.084 

0.079 

99.3 

Run 2 

1.045 

0.309 

70.4 

12.373 

0.084 

99.3 

Run 3 

0.804 

0.279 

65.3 

11.739 

0.120 

99.0 

Average 

0.928 

0.28• 

68.8 

11.732 

0'.094 

99.2 

FIGURE 1 

Redland Brick 

Tunnel Kiln Scrubber Inlet 

Cushwa Plant, Williamsport, Maryland 

Bend 

to 

Scrubber 

i----] A 

QB • 

Flow 

Bend 

From 

,i 

Traverse Points 

1 

2 

3 

4 

5 

6 

.7 

8 

9 

10 

11 

12 

Innex Distance (inches) 

1.0 

2.6 

4.6 

6.9 

9.8 

13.9 

25.1 

29.3 

32.1 

34.4 

36.4 

38.0 
FIGURE 2 

Redland Brick 

Tunnel Kiln Scrubber Stack 

Cushwa Plant, Williamsport, Maryland 

Flow 

50' 

Traverse Points 

1 

2 

3 

4 

5 

6 

Inner Distance (Inches) 

1.9 

6.4 

13.0 

31.0 

37.6 

42.1 

Fan