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 

SUMMARY AND DISCUSSION OF RESULTS .......................................................... 7 

PROCESS DESCRIPTION .......................................................................................... 16 

SAMPLE POINT LOCATION ..................................................................................... 17 

HYDROGEN CHLORIDE, HYDROGEN FLOURIDE, AND PARTICULATE 

SAMPLING PROCEDURE (EPA Method 26a/5) ....................................................... 18 

Particulate Sample Recovery ................................................................................... 20 

Halides and Halogens Sample Recovery ................................................................. 20 

Particulate Analytical Procedures ........................................................................... 21 

Hydrogen Chloride and Hydrogen Flouride Analytical Procedures ...................... 21 

QUALITY ASSURANCE ............................................................................................. 22 

Calibrations .............................................................................................................. 23 

Pi tot Tubes ............................................................................................................ 23 

Differential Pressure 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 LABORATORY ANALYSES ........................................................... 50 

Henry Brick Company, Inc. Selma, AL 
Sanders Engineering & 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 of the 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 of Environmental Management. The tests were conducted by Mr. 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 

of Henry 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 of Environmental Management. 

Henry Brick 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 of tests. 

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 of the sampling train are presented in Section 

6. The field data sheets for this testing are presented in Appendix B. Sample 

calculations of Run 1 are presented in Appendix 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 

Henry Brick Company, Inc. 5 Selma,AL 
Sanders Engineering & 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 of the laboratory analyses are 

included in Appendix D. 

Henry Brick Company, Inc. 6 Selma, AL 
Sanders Engineering & Analytical Services, Inc. Mobile, AL 

3. SUMMARY AND 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 of results for each of the parameters is presented below. 

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 of Environmental Management. 

Henry Brick Company, Inc. 7 Selma, AL 
Sanders Engineering & Analytical Services, Inc. Mobile, AL 

TABLE I. PARTICULATE, HYDROGEN CHLORIDE, AND 

HYDROGEN FLUORIDE TEST RESULTS 

HENRY BRICK COMPANY, INC. 

NO. 1 BRICK KILN EXHAUST STACK 

SELMA, ALABAMA 

Title of Run RUN! RUN2 RUN3 

Date Month/Day/Year 4/11/2006 4/1112006 4/11/2006 

Sampling Time -Start Military 0955 1138 1310 

Sampling Time -Stop Military 1059 1240 1413 

Number of Ports dimensionless 

Number of Points per Port dimensionless 10 10 10 

Production Rate Tons per Hour 12.6 12.6 12.6 

Stack Static Pressure Inches Water 0.20 0.20 0.20 

Barometric Pressure 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 of Gas Metered Actual Cubic Feet 32.465 32.740 34.605 

Volume of Water Collected Milliliters 71.00 83.00 70.00 

Sampling Time 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 of Stack Square Feet 8.727 8.727 8.727 

Avg. Sqr. Root Velocity Pressure Inches Water 0.5379 0.5334 0.5508 

Average Orifice Pressure (.C!.H) Inches Water 1.2185 1.2305 1.3175 

Average Stack Temperature Degrees F 316 313 323 

Average Meter Temperature Degrees F 66 72 80 

Final Volume of Acid Solution Milliliters 263 285 290 

Cone. of ACID Chloride Collected ug/ml 40.0 34.0 32.0 

Cone. of ACID Chloride in Blank ug/ml 0.00 0.00 0.00 

Cone. of ACID Flouride Collected ug/ml 2.2 2.1 2.0 

Cone. of ACID Flouride in Blank uglml 0.00 0.00 0.00 

Calculations 

RUN! RUN2 RUN 3 AVERAGE 

Volume of Gas Sampled Standanl Dry 33.300 33.185 34.608 33.698 

Cubic Feet 

Molecular Wt. of Stack Gas (dry) LB/LB-MOLE 28.14 27.98 28.19 28.11 

Water vapor in Stack Gas Percent 9.1 10.5 8.7 9.4 

Average Stack Gas Velocity Feet per second 36.9 36.7 38.0 37.2 

Stack Gas Flow Rate Actual Cubic 19,342 19,193 19,873 19,469 

Feet Per Minute 

Stack Gas Flow Rate Standard Wet Cubic 13,254 13,208 13,502 13,321 

Feet Per Minute 

Stack Gas Flow Rate Standard Dry Cubic 12,045 11,817 12,329 12,064 

Feet Per Minute 

Stack Gas Flow Rate Pounds of Dry 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 per Actual 0.0030 0.0098 0.0119 0.0082 

Cubic Foot 

Particulate Emission Rate Pounds per Hour 0.5 1.6 2.0 1.4 

Particulate Emission 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 

Test Equipment Quality Control 

Post Test Meter Correction Factor dimensionless 1.02 1.03 1.01 1.02 

Percent Difference Allowed5% 0.85 1.38 -0.47 0.59 

Cone. of Hydrogen Chloride ppm 7.569 6.996 6.424 6.996 

Hydrogen Chloride Mass Rate Pounds per Hour 0.518 0.470 0.450 0.479 

Hydrogen Chloride Mass Rate Pounds per Ton 0.04 0.04 0.04 0.04 

Allowable 0.26 0.26 0.26 0.26 

Cone. of Hydrogen Flouride ppm 0.74 0.77 0.71 0.74 

Hydrogen Flouride Mass Rate Pounds per Hour O.Q3 0.03 O.Q3 0.03 

Hydrogen Flouride Mass Rate Pounds per Ton 0.002 0.002 0.002 0.002 

Allowable 0.057 0.057 0.057 0.057 

Henry Brick Company, Inc. 8 Selma, AL 
Sanders Engineering & Analytical Services, Inc. 

TABLE II. PARTICULATE, HYDROGEN CHLORIDE, 

AND HYDROGEN FLUORIDE TEST RESULTS 

HENRY BRICK COMPANY, INC. 

NO.2 BRICK KILN EXHAUST STACK 

SELMA, ALABAMA 

Title of Run 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 of Ports dimensionless 2 

Number of Points per Port dimensionless 10 10 10 

Production Rate Tons per Hour 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 Mole Percent 02 16.5 15.5 14.8 

Carbon Dioxide Concentration Mole Percent C02 3.0 4.0 4.0 

Volume of Gas Metered Actual Cubic Feet 35.360 37.759 37.329 

Volume of Water Collected Milliliters 82.00 97.00 89.00 

Sampling Time Minutes 60 60 60 

Nozzle Diameter Inches 0.290 0.290 0.290 

Weight of Solids Collected Milligrams 12.0 16.4 14.3 

Area of Stack 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 

Average Meter Temperature Degrees F 91 94 96 

Final Volume of Acid Solution Milliliters 266 285 288 

Cone. of ACID Chloride Collected u!Yml 32.00 31.00 29.00 

Cone. of ACID Chloride in Blank uwml 0.00 0.00 0.00 

Cone. of ACID Fluoride Collected uwml 4.20 2.40 2.30 

Cone. of ACID Fluoride in Blank uwml 0.00 0.00 0.00 

Calculations 

RUN! RUN2 J!!lli1 AVERAGE 

Volume of Gas Sampled Standard Dry 35.98 38.25 37.69 37.31 

Cubic Feet 

Molecular Wt. of Stack Gas (dry) LBILB-MOLE 28.06 28.06 28.11 28.08 

Water vapor in Stack Gas Percent 9.7 10.7 10.0 10.1 

Average Stack Gas Velocity Feet per second 40.6 41.9 41.5 41.4 

Stack Gas Flow Rate Actual Cubic 21,277 21,963 21,741 21,660 

Feet Per Minute 

Stack Gas Flow Rate Standard Wet Cubic 12,597 12,879 12,719 12,732 

Feet Per Minute 

Stack Gas Flow Rate Standard Dry Cubic 11,376 11,506 11,447 11,443 

Feet Per Minute 

Stack Gas Flow Rate Pounds of Dry Air 852 862 857 857.1 

Per Minute 

Particulate Concentration Grains per Standard 0.0051 0.0066 0.0058 0.006 

Dry Cubic Foot 

Particulate Concentration Grains per Actual 0.0027 0.0035 0.0031 0.003 

Cubic Foot 

Particulate Emission Rate Pounds per Hour 0.5 0.7 0.6 0.575 

Particulate Emission Rate Pounds per Ton 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. of Hydrogen Chloride ppm 5.668 5.534 5.309 5.504 

Hydrogen Chloride Mass Rate Pounds per Hour 0.366 0.362 0.345 0.358 

Hydrogen Chloride Mass Rate Pounds per Ton 0.03 O.Q3 O.Q3 0.030 

Allowable 0.26 0.26 0.26 0.26 

Cone. of Hydrogen Flouride ppm 1.32 0.76 0.75 0.941 

Hydrogen Flouride Mass Rate Pounds per Hour 0.05 0.03 0.03 0.034 

Hydrogen Flouride Mass Rate Pounds per Ton 0.004 0.002 0.002 0.003 

Allowable 0.057 0.057 0.057 0.057 

Henry Brick Company, Inc. 12 

Mobile, AL 

Selma,AL