Entec Sewices, Inc. 

!6 D Commerce Avenue 

Hueytown, Alabama 35023 

Telephone: (205) 491-6676 

Fax: (205) 491-6614 

Results of the January 20, 2006 

RATA/Co•liance Testing for Gaseous Emissions on the 

Brick Plant No. 8 Tunnel Kilns. located in 

Sugarcreek, Ohio 

Facility Permit No. 06-79.00-0118, ID No, P801, P802, & P803 

Subm•ed to: 

Belden Brick Company 

475 Dover Road 

<\ Sugarcreek, Ohio •681 

A•ntion: Mr. John •:nsen 

Entec Project No. 26108 

Project Leader 

Report Submitted: February 9, 2006 

Reviewed By: 

Tom Lotz St. 

QA/QC Manager/Project Manager 

hereby certify to the best of myknowledge all field sampling and laboretofi analysis performed 

for this report is authentic and accurate, ti has been checked for ¢ompleteriess and accuracy. 
Belden BHck Company 

Table of Con•n• 

•¢tion 

Executive Summary 

Compliance Emissions Summary 

Relative Accuracy Test Results 

Sulfur Dioxide 

Detailed Te•t Results 

Sampling Procedures 

Location of Test Ports 

Diagram of Sampling Train 

RATA RM and CEM's Reid Data 

Volumetric Flow-Field Data 

Production Data 

Quality Assurance / Quality Control Procedures 

Analyzer Interference Checks 

NOx Converter Efficiency Test 

Instrumental Analyzer Calibrations 

Calibration Gas Certificates 

Flow Equipment Calibrations 

Nomenclature and Test Calculations 

Page No. 

1 

2 

3 

4 

9 

14 

1,5 

17 

63 

76 

80 

92 

95 

97 

108 

12'1 
Executive Summary, 

Entec Services, Inc. was retained by Belden Brick Company to perform a RATA on the 

CEM unit and compliance gaseous emissions testing on Bdck Plant No. 8 Tunnel Kilns 

located in Sugarcreek, Ohio. The control devices for the kiln are a dry scrubber and a 

baghouse. The Opsis CEM is composed of one analyzer. The analyzer uses an 

infrared (IR) detector that analyzes the gas stream for NOx, CO and SO2. The analyzer 

shoots the IR across the stack to let the gas combine with the projected light source. A 

detector at the other side of the stack picks up the light source influenced by the gas 

stream and transmits via fiber optic cable the signal to be processed by a interferometer 

located with the signal processing equipment in the cabinet. This "spectra is then 

turned into a direct ppm measurement. 

Mr. Erik Groth and Mr. Tommy Lotz, Jr, of Entec Services, Inc conducted the testing on 

January 20, 2006. Mr. John Jensen was present from Belden Brick and to coordinate 

testing with control room activities. 

No difficulties were encountered in the field collection of the samples or in the 

laboratory analysis of the samples by Entec Services, Inc. 

The gaseous emissions test summary on the following page gives a detailed summary 

of each paired test run compared to the maximum emission limits set forth by the State 

of Ohio Environmental Protection Agency, Tests results indicats the average 

gaseous emissions are below the limits set fo• by the Ststs of Ohio EPA for 

Facility Permit No. 06-79-00-0118, Facility Source Identification No. P801, P802, & 

P803. 

The RATA test summaries on the following pages give a summary of the CEM's 

calculated emissions, reference method calculated emissions and the calculated 

relative accuracy for the CEM's emissions. Test results indicate that the RATA 

results are below the limits for SO2 as set forth by the Code of Federal 

Regulations (CFR) 40 Part 60, Appendix B, and Performance Specification 2 and 

6. 


Relative Accuracy Determination 

SO2 

Test Performed For:. 

Betden Brick 

Sugarcreek, Ohio 

Plant N•. 8 

RATA and Emissions Testing 

Date:l/20106 

Run Date of Start Stop SO• RM 

Number Run Time Time tbsthr 

Test Performed By: 

Entec Services, Inc. 

Birmingham 

Trailer 903 

T. Lotz, Jr. 

CEM SN: AR-503-E-2951No. 0791 

CEM Difference 

tbslhr Like Ibs/hr 

Run 1 20-Jan 12:15:15 12:36:15 1t8.12 90.30 27,82 

Run 2 20-Jan 13:10:30 13:31:30 114.61 86,80 27,81 

Run3 20•Jan 13:50:15 14:11:t5 100.30 9t.20 9.10 

Run 4 20-Jan 14:33•15 14:54:15 103.38 94.69 8.69 

Run 5 20-Jan t5:07:15 15:28:15 97.94 84.54 13.40 

Run 6 20-Jan 15:41:15 16:02:15 96.79 92.66 4.13 

Run 7 20-Jan t6:16:15 16:37:15 104.83 99.66 5.17 

Run 8 20-Jan 16:50:15 17:11:15 104.83 99.66 5.17 

Run 9 20-Jan t7:23:00 17:44:00 104.83 99.66 5.17 

Ave•',•ge: 105.07 93.24 11.83 lbsthr 

Method of RA Determination: Applicable Standard 

Standard Deviation: 

Confidence Coefficient: 

T-Factor. 

Number of runs Reported: 

Applicable Standard: 

Relative Accuracy: 

Maximum RA 

RA Status 

9,5077 

7.3083 

2.306 

9 

355.5 ]bs/hr 

5.4 % 

I0.0 % 

Passed 

SOURCE OWNER: 

PLANT LOCATION: 

SOURCE(S) NAME(S): 

SOURCE(S) CONDITION: 

SOURCE(S) S•PE: 

SOURCE PERMIT NUMBER: 

TEST PERFORMED: 

REFERENCE METHOD TESTS: 

PROJECT •NAGER 

ENVIRONMENTAL ANALYST PROJECT LEADER 

ENVIRONMENTAL ANALYST ASSISTA• 

OWNER'S REPRESENTATP4E: 

RULING AGENCY 

RULING AGENCY REPRESENTATIVE: 

DATES TESTS CONDUCTED: 

ENTEC PROJECT NUMBER: 

Entec Sewices, Inc. 

SOURCE VERVIEW 

Betden Brick 

Sugarcreek, Ohio 

Plant No. 8 

Initia• RATA and Emissions Testing 

Circular 

23-X345 

Gaseous Testing 

Samp• Location 

Volumetrio Flow 

Molecular Weight 

Moisture Content 

SulfiJr Dioxide 

Oxides of Nitrogen 

C•rbon Monoxide 

Mr. Tom Lotz, Sr. 

Mr. Tommy Lotz, Jr. 

Mr. Edk Groth 

Mr. John Jensen 

Ohio EPA 

none 

01t19J'06 

26108 

EPA Method 

EPA Method 

EPA Method 

FT-IR 

EPA Met,hod 

EPA Method 

EPA Method 

2 

3 

6C 

7E 

t0 



Procedures 

The relative accuracy test results and the emission tests were determined using EPA 

Methods 1, 2, 3A, 4 (by FT-IR), 6C, 7E, and 10 CFR Title 40, Part 60, Appendix A; 

Appendix B performance specification 2 for Sulfur dioxide, and performance 

specification 6 for flow rates. The calibration and quality assurance procedures of EPA 

CFR 40 Part 60 Appendix A for all methods, and the "Quality Assurance Handbook for 

Air Pollution Measurement System" Volume tli Stationary Source-Specific Methods 

were followed throughout the duration of the field and laboratory testing. 

The most current revision revised as of July 1, 2004, of each method (as described in 

the Federal Register) was used. 

To satisfy the certification requirements for the CEMS data accuracy assessment of the 

applicable performance specifica•ons in 40 CFR 60, Appendix B, the relative accuracy 

test must have a minimum of nine test runs. If more than 9 test runs are performed a 

maximum of three sets of the test results may be rejected so long as the total number 

of test results used to determine the relative accuracy is greater than or equal to nine. 

However, atl data must be reported including the rejected data. The relative accuracy 

performance specification of the CEM'S must be no greater than 20 percent of the 

mean value of the reference data in units of the emission or 10 percent of the 

applicable standard, which ever is greater. Each run was twenty-one minutes long. 

Stack Gas Volumetric Flow 

The velocity of the gas stream was determined according to EPA Reference Method 1 

and 2 by reading the instantaneous velocity head with an inclined manometer at each 

sampling point with a calibrated S-type pitot tube attached adjacent to the sample 

nozzle. The stack pressure was measured with the static side of an S-type pitot tube. 

A calibrated pyrometer was used to measure stack temperature at each sampling point. 

The stack was tested for cyclonic flow according to EPA Reference Method 1. 
Stack Gas Molecular Weiflht-lnstrumental 

The carbon dioxide concentrations were determined using EPA Reference Method 3A. 

The molecular weight of the gas was calculated using the moisture, oxygen and carbon 

dioxide content and the measured stack gas temperature. 

Moisture Content 

The moisture content used for calculating the gas stream flow rate was determined by 

measuring the amount of moisture using a Temet DX 4000 FT-iR analyzer. 

Oxvclen 

The oxygen content in the flue gas was determined using a Siemens Oxymat 6I 

oxygen analyzer. The Oxymat 61 uses paramagnetic analysis. Oxygen is attracted into 

a strong magnetic field. Oxygen molecules in an inhomogeneous magnetic field are 

drawn in the direction of the increased field strength due to the paramagnetism When 

two gases with different oxygen concentrations meet in a magnetic field, a pressure 

difference is produced between them. One of the gases is a reference gas (N2), the 

other is the sample gas. The reference gas is introduced into the sample chamber 

through two channels. One of these reference gas streams meets the sample gas 

within the area of a magnetic field. Because the two channels are connected, the 

pressure, which is proportional to the oxygen concentration, causes a flow. This flow is 

converted into and electric signal by a microfiow sensor. This current is then amplified 

and provides a signal output of 4-20ma signals, which corresponds to a full-scale range 

of 0-25% oxygen, 

Carbon Dioxide 

Carbon dioxide concentrations were continuously measured with a Siemens Ultramat 

23 non-dispersive infrared (NDIR) analyzer. The theory of operation for this analyzer is 

based on the principle that CO2 has a unique absorption line spectrum in the infrared 

region. The instrument consists of an infrared light source, a chopper, a measurement 

cell, and a detector. The infrared light beam emitted by the source passes through the 

measuring cell, which is filled with a continuously flowing gas sample. The light beam is 

partially absorbed or attenuated by the gas species of interest in this cell before 

reaching the front chamber of the detector. Both the front and rear chambers of the 

sealed detector are filled with a reference gas, The difference in the amount of light 
absorbed between the front and rear chambers are dependent on the concentration of 

the gas species of interest within the sample measurement cell; a pressure differential 

is thus created between the two chambers. This pressure difference is then observed 

as gas flow by the micro-flow sensor located in a channel connecting the two chambers. 

The resulting AC signal from the micro-flow sensor is rectified, amplified and lineadzed 

into a 4-20ma signal for output that corresponds to a full-scale 0-25% measurement 

range. 

Sulfur Dioxide 

A Western Research Model 721-AT SO2 analyzer provided continuous analysis of SO2 

in the gas stream. The basic analytical principle involves quantitative measurement of 

the absorption of UV radiation by SO2 molecules. The analyzer uses a single light 

source, which emits an appropriate wavelength, illuminating the sample ceil through 

which the sample is continuously passed. Narrow-band optical filters are rotated 

through the beam, and the radiation passed through the optical filters and sample cell is 

detected by a single photo-detector. The signal pulses from the photo-detector are 

separated by a multi-plexor into a measuring channel and a reference channel• A log 

ratio amplifier computes the logarithm of the input signal ration, producing a signal that 

is proportional to the SO2 concentration. The dual-range analyzer has a digital readout, 

as well as 0-10.0 V DC output terminals. The full scale of the instrument was set at 

1000 ppm. 

Nitrogen Oxides 

An Advanced Pollution Instruments (APt) Model 200AH NOx analyzer, which operates 

on the basis of chemiluminescences, was used continuously to determine the NOx 

concentration in the effluent, The sample is initially routed through a converter where 

the NO2 is dissociated to form NO. The sample is then passed through a reaction 

chamber where the NO is quantitatively converted to NO2 by gas-phase oxidation with 

ozone produced within the analyzer. In this reaction, the NO2 molecules are elevated to 

an e•ectronicalty excited state and then immediately revert to a non-excited ground 

state. This reversion is accompanied by emission of photons (luminescent light), which 

impinge on a photo-multiplier detector and generate a low-level direct current. The NO• 

concentration measured by the instrument includes the contributions of both the NO in 

the effluent and the NO resulting from the dissociation of NO• Instrument outputs 
include an analog readout and 0-10 V DC output terminals. Full-scale response of the 

analyzer was set at 51 ppm throughout the test period. 

Carbon Monoxide 

The CO emissions were measured using a Siemens Ultramat 23 analyzer. This monet 

is a selective non-dispersive infrared radiation (NDIR) gas analyzer that operates on the 

infrared double-beam alternating light principle. The full range for the CO component of 

this instrument throughout the test period was 1000 ppm. 

Saml•linfl System 

Samples were extracted from the gas stream by a heated stainless steel probe 

maintained at a set temperature of 250 degrees Fahrenheit, through a ten (10) foot 

heated sample line that was heated to a temperature between 225 and 250 degrees, 

through a chilled sample conditioner to remove the moisture in the gas stream and 

transported to the test trailer through unheated teflon sample lines to the analyzers. 

pata Acquisition 

Concentration values were collected using a Baldwin Environmental RM Plus 

Parametrics data acquisition system. The data was recorded every' fifteen-seconds and 

then averaged for each sixty-second interval. Each minute average was then averaged 

for the duration of each test run. 

During all testing, the unit was operating within normal operating parameters; at a range 

appropriate in accordance with applicable permits. 
Entec Services, inc 

I6 D Commerce Ave, Hue•n, AL 35023 

STACK DRAWING & TRAVERSE POINT LOCATION 

Client: Belden Brick 

Source: Plant No, 8 

Type of T•erse: Vek:• (V) or Pa•¢ule• (•: • 

S•k D•m•t, inch.: 63 

S• H•gh• • •:• 

U•m D•n•: 312•0 ¢9• 

Do•m D•a•e: •0 3.8t 

Port TYro 

$•ck Am, Ft•: 

Number of Ports: 

Job NO. 26108 

Inp• By: Tommy Lotz, Jr, 

Nipple Port Diameter 

Length of Port, inches: 

Total Number of Traverse Points: 

l•umb•t of Point•: pet diam--. 

4.0" 

2 

$ 

312.0 

240; iNCHES 

Inside St•ck Outside Nipple 

2.0 6,0 

6,8 10.6 

20.3 

•,4 •4 

RATA 

10,7 t4.7 

31.5 35•5 

52.3 •6,3 

Adjured points ¢•iamet•¢ > 24" no point closet than 1,0 inch 

Ad}us•¢l po|nls diamet•)r 24 no point closer than 0,5 inch 

Stack Diametera between •2-24 inches minimum points am 8 

4 points per po•t if the 8 2 diameters downstream and 

•ps•mam cdter•a Is met. 
Instrument Sampling Train 

NOx 

CO 

so= 

co= 

o= 
FT-IR Sampling Train 

Gas