## Sanders Engineering & 

## Analytical Services, Inc. Mobile, AL
TABLE OF CONTENTS


## INTRODUCTION .......................................................................................................... 4 DESCRIPTION OF SAMPLING PROGRAM............................................................... 5 Particulate Testing..................................................................................................... 5 Hydrogen Chloride and Hydrogen Fluoride Testing ................................................ 5 SUMMARYAND DISCUSSION OF RESULTS .......................................................... 7 PROCESS DESCRIPTION.......................................................................................... 16 SAMPLE POINT LOCATION..................................................................................... 17 HYDROGEN CHLORIDE, HYDROGENFLOURIDE, AND PARTICULATE SAMPLING PROCEDURE (EPAMethod 26a/5) ....................................................... 18 Particulate Sample Recovery................................................................................... 20 Halides and Halogens Sample Recovery................................................................. 20 Particulate Analytical Procedures........................................................................... 21 Hydrogen Chloride and Hydrogen Flouride AnalyticalProcedures
...................... 21 QUALITYASSURANCE ............................................................................................. 22 Calibrations.............................................................................................................. 23 Pi tot Tubes............................................................................................................ 23 DifferentialPressure Gauges............................................................................... 23 Temperature Sensors ........................................................................................... 24 Nozzles .................................................................................................................. 24 Dry Gas Meter ...................................................................................................... 24 Orifice.................................................................................................................... 25 APPENDIX A QUALITY CONTROL OF TESTING EQUIPMENT
..................... 26 APPENDIX B FIELD DATA SHEETS ................................................................... 33 APPENDIX C SAMPLE CALCULATIONS............................................................ 43 APPENDIX D LABORATORYANALYSES ........................................................... 50



## HenryBrick Company, Inc. Selma, AL

## SandersEngineering & 

## Analytical Services, Inc. Mobile, AL

1. INTRODUCTION

Sanders Engineering 

## & Analytical Services, Inc. (SEAS) performed particulate, hydrogen chloride, and hydrogen fluoride emissions testing April 11, 

## 2006, for Henry Brick Company, Inc. on the Nos. 1 

## and 2 Brick Kiln Exhaust Stacks located at the Selma, Alabama facility. The testing was performed in accordance with the applicable U.S. EPA procedures specified at 

## 40 CFR, Part 60, Appendix A, Methods 1, 2, 3a, 4, 5, and 26a. Further discussions of the test methods are included later in the report. The purpose ofthe testing was to demonstrate compliance with the rules and regulations of the U. S. Environmental Protection Agency, and to meet the necessary requirements contained in the permit to operate issued by the Alabama Department ofEnvironmentalManagement. The tests were conductedbyMr. Isaac Smith, Mr. Mark Christian, Mr. Ryan Powell, and Mr. John Rampulla of Sanders Engineering & 

## Analytical Services, Inc., and were coordinated with Mr. Ken Smith ofHenry Brick Company, Inc. The results of the testing prove the units to be in compliance with the emission limitations contained in the permit to operate issued by the Alabama Department ofEnvironmentalManagement.



## HenryBrick Company, Inc. 4 

## Selma, AL

## Sanders Engineering 

## & Analytical Services, Inc. Mobile, AL

2. DESCRIPTION OF SAMPLING PROGRAM

The sampling program for Henry Brick Company, Inc. consisted of particulate, hydrogen chloride, and hydrogen fluoride emissions testing m compliance with US EPA methods. The following is a brief description of these types oftests.



## 2.1. Particulate Testing
The particulate sample was extracted from the stack isokinetically through a stainless steel nozzle and probe onto a pre-weighed glass fiber filter. The sample
was taken at a series of points across the stack. Each point represented an equal

area of stack. The isokinetic sampling rate and volumetric flow rate were monitored by an S-type pitot tube attached to the probe. Calibrations of the particulate testing equipment including pitots, thermocouples, magnehelics, and other measurement devices are included in Appendix A. A detailed description of the testing procedures and schematic ofthe sampling train are presented in Section 6. The field data sheets for this testing are presented in Appendix B. Sample calculations ofRun 1 are presented inAppendix C. 

## 2.2. Hydrogen Chloride and Hydrogen Fluoride Testing The quantitative determination of hydrogen chloride and hydrogen fluoride

was made in accordance with 40 CFR, Part 60, Appendix A, Method 26a. This test procedure requires the insertion of a glass sample probe into the gas stream. Stack gases are extracted isokinetically into a chilled impinger containing weak sulfuric acid as the absorbent media. Upon leaving the impinger, the gases pass through a silica gel absorption tube for collection of any remaining moisture before 

## HenryBrick Company, Inc. 5 

## Selma,AL

## SandersEngineering & 

## Analytical Services, Inc. Mobile, AL

entering the gas metering system. The collected sample is analyzed by ion chromatography. Calibrations of the testing equipment including pitots, thermocouples, magnehelics, and other measurement devices are included in Appendix A. A detailed description of the testing procedures and schematic of the sampling train is presented in Section 7. The results ofthe laboratory analyses are included in Appendix D.



## HenryBrick Company, Inc. 6 

## Selma, AL

# Sanders Engineering &

# Analytical Services, Inc. Mobile, AL

3. SUMMARYAND DISCUSSION OF RESULTS

There were no unusual problems encountered during the performance of the testing. The results of the particulate, hydrogen chloride, and hydrogen fluoride testing for the Nos. 1 and 2 Brick Kiln Exhaust Stacks are presented in Tables I and II. Graphical representation of the test results is presented in Figures 1 through 6. The summary ofresults for each ofthe parameters is presentedbelow.



## UNIT PARAMETER Actual Allowable Emissions Emissions No.1 Kiln Particulate 0.109 lbs/ton 0.42 lbs/ton No.1 Kiln Hydrogen Chloride 0.04lbs/ton 0.26 lbs/ton No.1 Kiln Hydrogen Fluoride 0.002lbs/ton 0.057 lbs/ton No.2 Kiln Particulate 0.048lbs/ton 0.42 lbs/ton No.2 Kiln Hydrogen Chloride 0.030 lbs/ton 0.26 lbs/ton No.2 Kiln Hydrogen Fluoride 0.003lbs/ton 0.057lbs/ton

The results of the testing prove the units to be in compliance with the emission limitations contained in the permit to operate issued by the Alabama Department ofEnvironmentalManagement.



# HenryBrick Company, Inc. 7 

# Selma, AL

## Sanders Engineering & 

## Analytical Services, Inc. Mobile, AL

TABLE I. PARTICULATE, HYDROGEN CHLORIDE, AND HYDROGEN FLUORIDE TEST RESULTS HENRY BRICKCOMPANY, INC. NO. 1 BRICKKILN EXHAUST STACK SELMA, ALABAMA

Title ofRun RUN! RUN2 RUN3 Date Month/Day/Year 4/11/2006 4/1112006 4/11/2006 SamplingTime -Start Military 0955 1138 1310 SamplingTime -Stop Military 1059 1240 1413 Number ofPorts dimensionless Number ofPoints perPort dimensionless 10 10 10 Production Rate Tons perHour 12.6 12.6 12.6 Stack Static Pressure InchesWater 0.20 0.20 0.20 BarometricPressure Inches Mercury 30.12 30.12 30.12 Standard Orifice Pressure L)H@ Inches Water 2.288 2.288 2.288 Meter Correction Factor dimensionless 1.012 1.012 1.012 Oxygen Concentration Mole Percent 02 17.0 17.0 17.0 Carbon Dioxide Concentration Mole Percent C02 3.0 3.0 3.0 Volume ofGas Metered Actual Cubic Feet 32.465 32.740 34.605 Volume ofWater Collected Milliliters 71.00 83.00 70.00 SamplingTime Minutes 60 60 60 Nozzle Diameter Inches 0.275 0.275 0.275 Weight of Solids Collected Milligrams 10.5 34.2 43.0 Area ofStack Square Feet 8.727 8.727 8.727 Avg. Sqr. Root VelocityPressure Inches Water 0.5379 0.5334 0.5508 Average Orifice Pressure (.C!.H) Inches Water 1.2185 1.2305 1.3175 Average StackTemperature Degrees F 316 313 323 Average Meter Temperature Degrees F 66 72 80 Final Volume ofAcid Solution Milliliters 263 285 290 Cone. ofACID Chloride Collected ug/ml 40.0 34.0 32.0 Cone. ofACID Chloridein Blank ug/ml 0.00 0.00 0.00 Cone. ofACID Flouride Collected ug/ml 2.2 2.1 2.0 Cone. ofACID Flouridein Blank uglml 0.00 0.00 0.00 Calculations
RUN! RUN2 RUN 3 AVERAGE Volume ofGas Sampled StandanlDry 33.300 33.185 34.608 33.698 Cubic Feet MolecularWt. ofStack Gas (dry) LB/LB-MOLE 28.14 27.98 28.19 28.11 Watervapor in Stack Gas Percent 9.1 10.5 8.7 9.4 Average Stack Gas Velocity Feetpersecond 36.9 36.7 38.0 37.2 Stack Gas Flow Rate Actual Cubic 19,342 19,193 19,873 19,469 FeetPer Minute Stack Gas Flow Rate Standard Wet Cubic 13,254 13,208 13,502 13,321 FeetPer Minute Stack Gas Flow Rate Standard DryCubic 12,045 11,817 12,329 12,064 Feet PerMinute Stack Gas Flow Rate Pounds ofDry Air 902 885 923 904 Per Minute Particulate Concentration Grains per Standard 0.0049 0.0159 0.0191 0.0133 Dry Cubic Foot Particulate Concentration Grains perActual 0.0030 0.0098 0.0119 0.0082 Cubic Foot ParticulateEmission Rate Pounds per Hour 0.5 1.6 2.0 1.4 ParticulateEmission Rate Pounds per Ton 0.040 0.128 0.161 0.109 Allowable 0.42 0.42 0.42 0.42 Isokinetic Rate Percent 97.5 99.0 99.0 98.5 TestEquipment Quality Control PostTestMeter Correction Factor dimensionless 1.02 1.03 1.01 1.02 Percent Difference Allowed5% 0.85 1.38 -0.47 0.59 Cone. ofHydrogen Chloride ppm 7.569 6.996 6.424 6.996 Hydrogen ChlorideMass Rate Poundsper Hour 0.518 0.470 0.450 0.479 Hydrogen ChlorideMass Rate Pounds per Ton 0.04 0.04 0.04 0.04 Allowable 0.26 0.26 0.26 0.26 Cone. ofHydrogen Flouride ppm 0.74 0.77 0.71 0.74 Hydrogen FlourideMass Rate Poundsper Hour O.Q3 0.03 O.Q3 0.03 Hydrogen FlourideMass Rate Pounds per Ton 0.002 0.002 0.002 0.002 Allowable 0.057 0.057 0.057 0.057



## HenryBrick Company, Inc. 8 

## Selma, AL

## SandersEngineering & 

## Analytical Services, Inc.
TABLE II. PARTICULATE, HYDROGEN CHLORIDE, AND HYDROGEN FLUORIDE TEST RESULTS HENRY BRICKCOMPANY, INC. NO.2 BRICKKILN EXHAUST STACK SELMA, ALABAMA
TitleofRun RUN! RUN2 RUN3 Date Month/Day/Year 411112006 4/1112006 4/11/2006 Sampling Time -Start Military 1035 1218 1345 Sampling Time-Stop Military 1135 1318 1445 Number ofPorts dimensionless 2 Number ofPoints per Port dimensionless 10 10 10 Production Rate Tons perHour 12.1 12.1 12.1 Stack Static Pressure Inches Water 0.20 0.20 0.20 Barometric Pressure Inches Mercury 30.12 30.12 30.12 Standard Orifice Pressure**8~** Inches Water 1.988 1.988 1.988 Meter Correction Factor dimensionless 1.052 1.052 1.052 Oxygen Concentration MolePercent 02 16.5 15.5 14.8 Carbon Dioxide Concentration MolePercent C02 3.0 4.0 4.0 VolumeofGas Metered Actual CubicFeet 35.360 37.759 37.329 Volume ofWater Collected Milliliters 82.00 97.00 89.00 Sampling Time Minutes 60 60 60 Nozzle Diameter Inches 0.290 0.290 0.290 WeightofSolids Collected Milligrams 12.0 16.4 14.3 Area ofStack Square Feet 8.727 8.727 8.727 Avg. Sqr.Root Velocity Pressure Inches Water 0.5492 0.5642 0.5583 Average Orifice Pressure (AH) Inches Water 1.2 1.3 1.3 Average Stack Temperature Degrees F 438 447 449 AverageMeter Temperature Degrees F 91 94 96 FinalVolume ofAcid Solution Milliliters 266 285 288 Cone. ofACID Chloride Collected u!Yml 32.00 31.00 29.00 Cone. ofACID Chloride in Blank uwml 0.00 0.00 0.00 Cone. ofACID FluorideCollected uwml 4.20 2.40 2.30 Cone. ofACID Fluoride in Blank uwml 0.00 0.00 0.00 Calculations
RUN! RUN2 J!!lli1 AVERAGE VolumeofGas Sampled Standard Dry 35.98 38.25 37.69 37.31 CubicFeet MolecularWt. ofStackGas (dry) LBILB-MOLE 28.06 28.06 28.11 28.08 Watervapor in Stack Gas Percent 9.7 10.7 10.0 10.1 Average Stack Gas Velocity Feetper second 40.6 41.9 41.5 41.4 Stack Gas Flow Rate Actual Cubic 21,277 21,963 21,741 21,660 FeetPerMinute Stack Gas Flow Rate Standard WetCubic 12,597 12,879 12,719 12,732 FeetPerMinute Stack Gas Flow Rate Standard Dry Cubic 11,376 11,506 11,447 11,443 FeetPerMinute Stack Gas Flow Rate Pounds ofDry Air 852 862 857 857.1 PerMinute Particulate Concentration Grains per Standard 0.0051 0.0066 0.0058 0.006 DryCubicFoot Particulate Concentration Grains per Actual 0.0027 0.0035 0.0031 0.003 CubicFoot ParticulateEmission Rate Pounds perHour 0.5 0.7 0.6 0.575 ParticulateEmission Rate Pounds perTon 0.042 0.054 0.048 0.048 Allowable 0.42 0.42 0.42 0.42 Isokinetic Rate Percent 100.3 105.4 104.4 103.3 Cone. ofHydrogen Chloride ppm 5.668 5.534 5.309 5.504 Hydrogen ChlorideMass Rate Pounds perHour 0.366 0.362 0.345 0.358 Hydrogen ChlorideMass Rate Pounds perTon 0.03 O.Q3 O.Q3 0.030 Allowable 0.26 0.26 0.26 0.26 Cone. ofHydrogen Flouride ppm 1.32 0.76 0.75 0.941 Hydrogen Flouride Mass Rate PoundsperHour 0.05 0.03 0.03 0.034 Hydrogen FlourideMass Rate Pounds perTon 0.004 0.002 0.002 0.003 Allowable 0.057 0.057 0.057 0.057 

## HenryBrick Company, Inc. 12 

## Mobile, AL

Selma,AL