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•
•¢tionExecutive 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. 12349141,51763768092959710812'1Executive 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 2.3069 355.5 ]bs/hr 5.4 %I0.0 % PassedSOURCE

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

none01t19J'06 26108 EPA Method EPA Method EPA Method FT-IR EPA Met,hod EPA Method EPA Method

236C7Et0Procedures 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 lightabsorbed 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

outputsinclude 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

NOxCOso=co=o=FT-IR Sampling Train

Gas