AP-42 Section ~j•7— 

Reference } 

~ 

9 3 Report Envisage Environmental Incorporated REPORT NO. Reference ~ 

P.O. Box 152, Richfield, Ohio 44286 

COMPANY MPt 

___ 

Phone (216) 526-0990 

TITLEComy ~ ___ 

DATE 11-17/18-93 

F ~ 

u;L; UEC 2 I ~ 

METROPOLITAN CERAMICS 

CANTON, OHIO 

TUNNEL KILN #-3 ERHAUST STACK 

PARTICULATE, S02, NOs, HYDROFLUORIC ACID 

EMISSION EVALUATION 

CONDUCTED - NOVENBER 17-18, 1993 

I1-1-006 
SOURCE 

EVALUATION 

RESULTS 

PREPARED BY 

Envisage 

Environmental 

1 ncorporated ' 

P.O. Box 152 Richfield, Ohio 44286 

Phone (216) 526-0990 
Envisage Environmental Incorporated ° 

December 16, 1993 

Mr. Philip McGuinness 

Metropolitan Ceramics Inc. 

1201 Millerton Road S.E. 

Canton, Ohio 44707 

Dear Mr. McGuinness: 

The following report is the result of the particulate, hydrofluoric acid, nitrogen 

oxides, and sulfur dioxide emission evaluation conducted on November 17 & 18, 

1993 at the Metropolitan Ceramics Inc., Canton, Ohio. Testing was performed 

at the exhaust stack serving the # 3 Tunnel Kiln. 

The results are true and accurate to the degree specified in the pertinent sections 

of the Code of Federal Regulations , in force at the time of testing concerning 

source sampling for the above compounds. 

I am looking forward to answering any questions you may have and assisting you 

in the future. 

Respectfully submitted, 

~ 

Frank . ucky 

Manager, Source Sampling 

ENVISAGE ENVIRONMENTAL INC. 

P.O. Box 152 Richfield, Ohio 44286 Phone (216) 526-0990 Fax (216) 526-8555 

3 
TABLE OF CONTENTS 

PAGE NUMBER 

INTRODUCTION 3 

DESCRIPTION OF PROGRAM 5-6 

TEST RESULTS SUMMARY 8 

TEST RESULTS DETAILED 9- 9A 

SAMPLE POINT LOCATION DIAGRAM 11 

LABORATORY SECTION 13 - 17 

EMISSION SAMPLING EQUIPMENT SPECIFICATIONS 19 

FIELD DATA SHEETS 21 - 27 

CALIBRATION SECTION 29 - 32 

EMISSION SAMPLING NOMENCLATURE 34 - 35 

EMISSION SAMPLING CALCULATIONS 37 - 49 

CHART RECORDINGS 51 - 55 

' Envisage 

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Environmental 

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Incorporated 

P.O. Box 152 Rlohfieltl. Ohio 44266 

Phone (216) 526-0990 
2 

INTRODUCTION 

_ Envisage 

Environmental 

- Incorporated 

_ P.O. Box 152 Riohfield, Ohio 44266 

Phone (216) 526-0990 

~ 
3 

INTRODUCTION 

On November 17 & 18, 1993 Envisage Environmental Inc. conducted a particulate, 

hydrofluoric acid, nitrogen oxides, and sulfur dioxide emission evaluation at the Metropolitan 

Ceramics Inc., Canton, Ohio. The testing was performed at the exhaust stack serving the 

# 3 Tunnel Kiln. The operation of the kiln and systems involved were monitored throughout 

the duration of the testing by Metropolitan Ceramics Inc. personnel. 

The purpose of the evaluation was to determine the emission rates from the unit to verify 

complianc with the applicable emission limitations set forth by the Ohio EPA. The Envisage 

testing team consisted of Messrs. Gregory Sinkovich, James Gray, Eric Hevener, Jamie 

Kingsborough, David Donelson, and Terry Campbell. Mr. Philip McGuinness, Metropolitan 

Ceramics, coordinated the testing. The Ohio EPA was also present during the testing and 

was represented by Mr. Rick Miller. 

Results are presented in this report for pounds per hour. and grains per dry standard cubic 

foot of emitted particulate, hydrofluoric acid, nitrogen oxides, sulfur dioxide, as well as the 

various velocity, volumetric and temperature measurements associated with these tests. 

_ Envisage 

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Environmental 

Incorporated 

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P.O. 90x 152 Richlleld, Ohio 44266 

Phone (216) 526-0990 
4 

DESCRIPTION OF PROGRAM 

~ Envisage 

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P.O. Box 152 Riohlield. Ohio 44286 

Phone (216) 526-0990 

n 
5 

DESCRIPTION OF PROGRAM 

The testing was conducted at the exhaust stack serving the # 3 Tunnel Kiln. The emission 

test consisted of three (3) test runs of USEPA Methods 1- 5, 6C, 7E, and 13. Each of the 

tests were performed over a sixty (60) minute period. Test methods 1-2, 6C and 7E were 

performed on November 17, 1993, and test methods 1-5, and 13 were performed on 

November 18, 1993. 

Particulate and hydrofluoric acid sampling, consisted of twelve (12) sample/traverse points 

being utilized in each of the two (2) ports for a total of twenty four (24) sample/traverse points. 

The samples were withdrawn for two and one half (2.5) minutes at each sample/traverse 

point. Sampl re taken from the gas streams isokinetically through a.61 inch nozzle and 

• fve (5) foo Pyrex lined prob . The entire length of the probe was heated and attached to 

• standard EPA Method 1-5 sample train. The hot box temperature was maintained between 

223 and 273 degrees Fahrenheit. Exit gas temperature of the impingers was maintained 

below 68 degrees Fahrenheit with an ice bath. The nozzle, probe and connecting glassware 

were cleaned before testing and at the conclusion of each test run. Leak checks of the pitot 

tube lines and the sample train were all acceptable by EPA regulations. 

Testing for sulfur dioxide was performed in accordance with USEPA Method 6C, Determination 

of Sulfur Dioxide Emissions from Stationary Sources (instrumental analyzer procedure). A 

single representative sampling point was utilized in the gas stream, Samples were withdrawn 

at a constant rate through a heated Teflon sample line. Samples were relayed to a Bovar 

photometric infrared analyzer which performs continuous analysis of sulfur dioxide. 

Testing for nitrogen oxides was performed in accordance with USEPA Method 7E, 

Determination of Nitrogen Oxides Emissions from Stationary Sources. A single representative 

sampling point was utilized in the gas stream, Samples were withdrawn at a constant rate 

through a heated Teflon sample line. Samples were relayed to a Meloy Chemilumenizer which 

performs continuous analysis of total oxides of nitrogen 

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P.O. Box 152 RlohfiBltl, Ohio 44286 

Phone (216) 526-0990 
6 

DESCRIPTION OF PROGRAM - :: ).ntinued 

AII constant emission monitors were calibrated before and after each sample run with USEPA 

Protocol I calibration gases. 

Flue gas analysis was conducted by drawing an integrated air bag sample and analyzing it 

on a Hays Republic Model 621A "Orsat" Portable Gas Analyzer. The average of these readings 

for each run were used in calculating the emission rates. 

Calibration of the equipment used, including the dry gas meter, temperature measuring 

devices, orifice meter, and the "S" type pitot tube was conducted within 60 days of the test 

date. Copies of the data are included in this report. 

AII analytical procedures were performed in accordance with the methods specified in the 

Code of Federal Regulations, Title 40, Part 60, Volume 43. Blanks were collected and 

analyzed on the distilled water, and acetone used in the evaluation. The residue from the 

distilled water was less than could be measured on a 0.1 milligram analytical balance and was 

considered zero. The acetone blank was recorded and incorporated into the results. . 

The example equations included in this report uses the figures from Run # 1. 

_ Envlsage 

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Environmental 

Inoorporated 

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P.O. Boa 152 Richfleld. Ohio 44286 

Phone (216) 526-0990 
TEST RESULTS 

SUMMARY 

~ Envisage 

Environmental 

- Incorporated 

-

P.O. BCX 152 fllChfieltl. Ohio 44286 

Phone (216) 526-0990 

IA 
TEST RESULTS SUMMARY 0 

Metropolitan Ceramics 

Tunnel Kiln #3 Exhaust Stack 

PARAMETER 

Particulate Emissions 

Pounds/hour 

Grains/dscf 

NOx Emissions 

Pounds/hour 

Pounds/dscf 

Sulfur Dioxide Emissions 

Pounds/hour 

Pounds/dscf 

Hydrofluoric Acid Emissions 

Pounds/hour 

Grains/dscf 

System Flow Rates 

Feet/second 

ACFM 

DSCFM 

Moisture Content 

Volume percent 

Stack Temperature 

RUN # 1 RUN # 2 RUN # 3 

X 

3 l ! 0.9018 0.7821 0.8487 

0.0152 0.0132 0.0138 

/ 

= 3.05 2.59 3.13 ~ c/ 

6.18E-06 5.26E-06 6.07E-06 

2.05 2.05 1.88 ~ rl 

4.16E-06 4.16E-06 3.66E-06 

1.92 1.95 2.11 1, ~ 

0.0323 0.0328 0.0344 03; ~ 

8.91 8.89 9.11 

10,493 10,477 10,734 

6,928 6,916 7,160 

6.20 6.61 6.25 G.:~ 

262 258 254 

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Environmental 

_

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P.O. Boz 152 Riahtield, Ohio 44286 

Phone (216) 526-0990 

/ ) 

Z 

7 

~ 
8~ 

TEST RESULTS 

DETAILED 

- Envlsage 

Environmental 

- Incorporated 

 -

P.O. f3ox 152 Rlehfield, Ohio 44266 

Phone (216) 526-0990 

/~ 
Time of Day 

1 Gas Volume-dry,std. 

2 Condensate Vapor Vol. 

3 Gas Stream Moisture 

4 Mol.Wt-flue gas (dry) 

5 Mo1.Wt-flue gas (wet) 

6 Flue Gas Velocity 

~ 7 Flue Gas Volume-Actual 

~ 8 Flue Gas Volume-Std. 

9 Particulate Conc. 

- Probe 

- Filter 

- Hydrogen Fluoride 

- Total Particulate 

10 Emission Rate 

- Probe 

- Filter 

- Hydrogen Fluoride 

Total Particulate 

~

- 

11 Isokinetic Rate 

Symbol 

Vmstd 

Vwstd 

Bws 

Msd 

Ms 

Vs 

ACFM 

DSCFM 

Cs 

E 

I 

N 7,j, - 

~ 

`~ TEST RESULTS 

Metropolitan Ceramics 

Tunnel Kiln #3 Exhaust Stack 

SAMPLE TRAIN # 1 

Units RUN # 1 RUN # 2 RUN # 3 

0927 1046 1222 

1013 1150 1327 

cu. ft. 43.18 43.39 43.18 

cu. ft. 2.85 3.07 2.88 

vol.dec 0.0620 0.0661 0.0625 

lb/lb mo. 30.01 30.03 30.01 

lb/lb mo. 29.27 29.23 29.26 

ft/sec 8.91 8.89 9.11 

cu. ft. 10,493 10,477 10,734 

cu. ft. 6,928 6,916 7,160 '7¢ -*1 

gr/dscf 0.0034 0.0026 0.0031 

gr/dscf 0.0118 0.0106 0.0107 

gr/dscf 0.0323 0.0328 0.0344 

gr/dscf 0.0152 0.0132 0.0138 

lb/hr 0.2016 0.1539 0.1908 

lb/hr 0.7002 0.6282 0.6579 

lb/hr 1.9198 1.9456 2.1098 

lb/hr 0.9018 0.7821 0.8487 

% 100.5 101.2 97.2 

- Envlsage 

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- Incorporated 

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P.O. Box 152 tiICh11e10. OhiO 44286 

Phone (216) 526-0990 
Symbol 

Time of Day 

1 Gas Stream Moisture Bws 

2 Mo1.Wt-flue gas (dry) Msd 

3 Mo1.Wt-flue gas (wet) Ms 

4 Flue Gas Velocity Vs 

5 Flue Gas Volume-Actual ACFM 

6 Flue Gas Volume-Std. DSCFM 

7 Concentrations. Cs 

- Nitrogen Oxides 

- Sulfur Dioxide 

8 Emission Rate E 

- Nitrogen Oxides 

- Sulfur Dioxide 

TEST RESULTS 

. .I 

1 Metropolitan Ceramics 

Tunnel Kiln #3 Exhaust Stack 

Constant Monitor Sampling 

Units RUN # 1 RUN # 2 RUN # 3 

0927 1046 1222 

1013 1150 1327 

vol.dec 0.0643 0.0651 0.0491 

lb/lb mo. 30.01 30.03 30.01 

lb/lb mo. 29.24 29.24 29.42 

ft/sec 10.02 10.02 10.22 

cu. ft. 11,803 11,805 12,034 

cu . ft . 8,228 8,218 8,577 S J`l s 

lbs/dscf 6.18E-06 5.26E-06 6.07E-06 

lbs/dscf 4.16E-06 4.16E-06 3.66E-06 

lb/hr 3.05 2.59 3.13 

lb/hr 2.05 2.05 1.88 

i Envisage 

_ 

Environmental 

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Incorporated 

P.O. Box 152 Richlleld. Ohio 44286 

Phone (216) 526-0990 
SAMPLE POINT 

LOCATION DIAGRAM 

10 

~ Envisage 

Environmental 

- Incorporated 

_ P.O. 80x 152 RlOhfiBIG, OhiO 44266 

PhOne (216) 526-0990 

I 1(1~ 
SAMPLE POINT LOCATIONS 11 

Metropolitan Ceramics 

Canton, Ohio 

# 3 Tunnel Kiln Exhaust 

Inside Diameter = 

* 60 inches 

* 

* 

* 

* 

Z* 2 * 1 1* 

2 4 6 8 10 12 

* 

* 

* 

* 

* * 

Point # ------- 

D ~ nsiae eWarlQm ------------- 

Point # ------- D insaRe eWayQm ------------- 

1 58.7 inches 7 21.4 inches 

2 56.0 inches 8 15.0 inches 

3 52.9 inches 9 10.6 inches 

4 49.4 inches 10 7.1 inches 

5 45.0 inches 11 4.0 inches 

6 38.6 inches 12 1.3 inches 

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Environmental Incorporated 

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P.O. Box 152 FIehllBltl, OhiO 44266 

Phone (216) 526-0990 

IA 
LABORATORY SECTION 

12 

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Environmental 

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P.O. Box 152 Rithlield. OhiO 44286 

Phone (216) 526-0990 
LABORATORY SUMMARY SHEET 13 

Metropolitan Ceramics 

Tunnel Kiln #3 Exhaust Stack 

.SAMPLE TRAIN # 1 

_ Symbol Units RUN # 1 RUN # 2 RUN # 3 

1 Sampling Time t minutes 60.0 60.0 60.0 

2 Barometric Pressure Pb in. Hg 28.78 28.78 28.78 

3 Static Pressure Pg in. H20 -0.02 -0.02 -0.02 

Stack Pressure Ps in. Hg 28.78 28.78 28.78 

4 Gas Meter Volume Vm cu. ft. 45.06 45.83 45.79 

5 Stack Area A sq. ft. 19.63 19.63 19.63 

6 Nozzle Diameter Dn dec. in. 0.61 0.61 0.61 

7 Meter Temperature degrees F 72.1 78.6 80.1 

Tm degrees R 532.1 538.6 540.1 

8 Stack Temperature degrees F 261.5 258.5 253.8 

Ts degrees R 721.5 718.5 713.8 

9 Velocity Head ^P in. H20 0.134 0.134 0.138 

10 Orifice Pressure ^H in. H20 1.55 1.56 1.06 

11 Carbon dioxide CO2 9'0 8.4 8.5 8.4 

12 Oxygen 02 % 16.5 16.5 16.4 

13 Carbon monoxide CO % 0.0 0.0 0.0 

14 Nitrogen N2 9'0 75.1 75.0 75.1 

15 Pitot Coefficient Cp 0.84 0.84 0.84 

16 Water Collected Vlc ml 60.6 65.2 61.2 

Sample Weight: Mn 

17 - Probe g 0.0095 0.0073 0.0087 

18 - Filter g 0.0330 0.0298 0.0300 

19 - Hydrogen Fluoride g 0.0905 0.0923 0.0962 

Asi '1 

_ Envisage - Envlronmental 

_

Incorporated 

P.O. Boz 152 Richfield, Ohio 44286 

Phone (216) 526-0990 
LABORATORY SUMMARY SHEET 14 

Metropolitan Ceramics 

Tunnel Kiln #3 Exhaust Stack 

Constant Monitor Sampling 

Symbol Units RUN # 1 RUN # 2 RUN # 3 

1 Sampling Time t minutes 60.0 60.0 60.0 

2 Barometric Pressure Pb in. Hg 28.78 28.78 28.78 

3 Static Pressure Pg in. H20 -0.02 -0.02 -0.02 

Stack Pressure Ps in. Hg 28.78 28.78 28.78 

4 Stack Area A sq. ft. 19.63 19.63 19.63 

5 Stack Temperature degrees F 221.7 222.0 217.6 

Ts degrees R 681.7 682.0 677.6 

6 Velocity Head ^P in. H20 0.155 0.155 0.159 

7 Carbon dioxide CO2 % 8.4 8.5 8.4 

8 Oxygen 02 % 16.5 16.5 16.4 

9 Carbon monoxide CO 9'0 0.0 0.0 0.0 

10 Nitrogen N2 % 75.1 15.0 75.1 

11 Pitot Coefficient Cp 0.84 0.84 0.84 

12 Sample Weight: Mn 

- Nitrogen Oxides PPM 51.8 44.0 50.8 

- Sulfur Dioxide PPM 25.0 25.0 22.0 

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- Inoorporated 

P.O. Box 152 Rlohlieltl, Ohio 44266 

Phone (216) 526-0990 
12/15%93 13:51 MSL ANALYTI[,HL 001 

' ` ANALYTI cAL 

i 

7630 Mus p~xwnY, ~vaLaNO. otao 44tz 

~~+~v~~ES~ ~N~• 

PFIGN~: (216) 4r17•1550 FAX: (~~r) 447-071 

QL/ALITY 44I4TERIAL5 Fr ENVlROAIMENTAL TESTlN6 SINCE 194S 

I 

DAte: 15 December 1993 

Report#: 12073-33E 

ti.ab#: 17077-17082 

P4#: 

rl ~ wyrw40o61 •e,v. 

P.P. Box 152 

Ri~.hfield, OH 33288 

1 

Attn: Frank Hezoucky 

; 

i 

C11ent Description: Liquid/Filters J/'N 93-2007 

Env isaqe Descri ;Ltion Hvdrofluorlc Add (mcR) 

1 250 ml 380.0 

~ 2 255 ml 390.0 

f3 250 ml 30.0 

EMvisage Descrlolgn F-hrdroAuorlc Aaid (ugfflker) 

1 A 1008 NA 4$0.0 

2A 9S3 NA 400.0 

I 

3A 952 NA 1200.0° 

We certlfy the above anaiysls to be the true results based 

~ Ao9er 

e des}CtRated samples. 

Environmental Mana9er 
L}1clJnr+ I vn T I 

COMPANY J`1El--ko C.6'RANiC S 

~ 

DAi 

16 

LOCATION NQO 

RUN 

cAsrcwA 7E,:R 

IMF1NGcRS 

FiNAL a~. o b ~ ~ ' S'vr' e o 07 t3`d 

INITiAL o,ob oo.66 cp.o6 

NEi 

SIUCA GB? 

FiNAL 

INITtAL 

NE7 1o. ~ a.-Z ~ 1,•z, ~ ~ 

PARTiCULATE 

PROBE 

FiNAL ~~.~1 l~1 1~. 212~-J ' I~J• ~3~~ 

INRIAL 

NL f I I 

FLTEq 

1NNITL4 i ~~~ `(c~ I ~ `l-~~ L 

NET ! 

IMPINGERS 

FiNAL 

INRIAL 

NET 
EMISSION SAMPLING 

EQUIPMENT SPECIFICATIONS 

18 

~ Envisage 

~ 

Environmentai 

_

Incorporated 

P.O. Box 152 Richlield, Ohio 44286 

Phone (216) 526-0990 
ORSAT A:N+nL.YSIS WCRK S=~,T 17 

~ q 3 

fi-e .40 (~71Ir7 ~ C S 

OP'P .ki OR: 

RL-N ._ ~ 

~ I 1 1 2 11 3 1 1 

A=AZ. !NE 1 IAl.~ .~. INr t I A=J cA.l. I i 1 i 1 I AVE—a.—~,CE 

co, I ~S, ~ I ~S. H ~ ~. Y I~ y I 8~, ~ ~~ s 

o- I 2`+ cl I 16: s I 2 y q ► ~6. 5 I 2 s_o I i~ 5-1" 

co 1 I 1 a I 10 1 ,. 

RLiY T 2 

I 

ACTUAL I NET I ACNAL I NET I ACIUAL, IN7Ei' I AVE_AGE II 

CO, 

0,I Zs ~ Il~ .sl s,c~ I/~ ~ 2~,~ I~, rt I 

CO 

RL N, 

F 11=2 IL 3 I 

ACTT.iAL I NET I ACNALI NF.'T I ACNAT, I NEZ' I AVE.F.SGE 

co, ~ ~ g`f ~ 8; S 1 8- s 1 9, 1 1 8, Y I ~ 

o, I 2W g Il8.t-1 I 2L- .Ll 2y_ ~ 

co ~ z4. ~ I a 1 2 v. 2 H. I 

COIQAFENI'S: 

F~4-n Envisage 

Environmentaf 

- Incarporated 

_

P.C. S= iaz akam.a CNe..as 

ar+m. aim 5254M 

.lf~Q 
E:,ui-,ment and Specifications 

U.S.=.?.A. Re£arence methods 1-5 

19 

CantroL Uni: (Metar Box) 

Envisage Envi_onmental ?nc 

~~ndersoa Samplers 

qP.manL'fact'Sred R.A.C. 

JamIIle Bo2 -

_Remanufactured R.A.C. 

_S.3.I. Scecial Design 

EY:-=~ent 2esi3nat:on 

C:,nt=31 Unit 3'3 "S- 08 a 09 

Ccnt=el Unit #'s :B- 01 - 02 

Conr:ol Un_t #'s M9- 03 - 07 

SB- 0:, 02 a 05 - 07 

S=- 03 04 

SB- 08 - 11 

T~.pingers - per sample train (each set changed :or eaca test run) 

3:".adi=:ad Smi=h Grsenbur3 type 

1 Smith Greenburg type 

?=obes Length 

- ,_,I, 3 foot 

gE,E,I, 5 foot 

_- ,_,I_ 3 £oot 

_E.E.I. 7 £oot 

10 foot 

12 £oot 

15 £oot 

E.E.I. 24 £oot 

Tamperature Sensors 

Qaega Engineering 

2hermo Electric 

a:Fluke 51 

_Fisher Scientifie 

_Fisher Scientific 

Lin:ng types 

SS, P:Z...C, QUARIZ, 

SS, PY.R.'-ES, QUARTZ, TEFI.C:i 

SS, PYF_L, T:FLON 

SS , P'_'R:_'Y. T_: LON 

SS, P'r', T'.::F*_O:t 

SS, PYR:'Y, Ty.ZON 

SS, P':4.:.. 'Y, Z.FLON 

SS , Sy'LOH 

Equipment Designatioa 

PY- 01 & 02 

PY- 03 - 08 

PY- 01 - 02 - 03 - 04 - 05 

Mercury Thermometer 

Birietallie Thersametar 

Pressure Gauges 

-~K-Dayer Ineline Mmometer 

D~+yer Magnahelic 

~Dwper Magnehelie 

Dwryer "II" iube Manometer 

_Dwyer "U" Iube Manometer 

_Dayer Microtector (Micro - Manometer 

Type 

Oi1, 0- 10 ineh rater 

Magnetie/Machanieal 0- 1 ineh aater 

Magnetic/Meehanieal 0- 10 ineh watar 

Mercury, 36 inches 

Water, 72 inehes 

Water, 0- 1 inchea o£ vatar 

Deionized/ Distilled 

Reagent Grade (40.001Z residual) 

6 - 16 Mesh 

Acatcne- Insoluble & Heat Resistant 

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Chemicals and Reagents 

~-'/ Water 

Acetoae 

Silica Gel 

Stopcock Grease 
FIELD DATA SHEETS 

20 

_ Envisage - Environmental 

_

Incorporated 

P.O. f3ox 152 Rlchfleld. Ohio 44266 

Phone (216) 526-0990 
21 

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CALIBRATION SECTION 

K-~ 

~ Envlsage 

Envlronmental 

- Incorporated 

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P.O. Box 152 Riahlieltl. OhiO 44266 

Phone (216) 526-0990 
29 

CALIBRATION FREOUENCY 

The frequency of calibration is dictated by the Code of Federal ReQulations 

Volume 42, Number 160, August 18, 1977. The regulations state that you 

must "use methods and equipment which have been approved by the 

Administrator to calibrate the orifice meter, pitot tube, dry gas meter, and 

probe heater. Recalibrate after each test". 

The methods of calibration are determined from "maintenance, Calibration, 

and Operation of Isokinetic Source Sampling Equipment," published by the 

U.S.EPA Office of Air Program Publications APTD-0576. Per the above 

listed regulations, the equipment was checked after the stack test and values 

of Y, Cp(Test), and nozzle diameter had not appreciably changed from the 

acceptable tolerances. 

NOZZLE DIAi✓fETER CALIBRATION 

I.D. of nozzles are checked immediately prior to and immediately following 

the stack test. If the prior deviation exceeds +.001 inches on an average or 

+.002 inches maximum, the nozzle is reworked. 

BAROMETER CALIBRATION 

The aneroid barometers used by Envisage are calibrated to our mercury in 

glass barometer which is NBS traceable. Calibration occurs before and after 

each field use. 

i Envlsage 

Environmental 

_- Incorporated 

P.O. Box 152 RiChIIBIC. Ohia 44286 

Phone (216) 526-0990 
THERMOCOUPLE CALIBRATION 

DATE: September 30, 1993 

30 

Type: K low Medium 

Sensor # Reading Ref Reading Ref 

1 40 41 80 79 

2 40 40 79 79 

3 41 40 79 80 

4 40 40 79 79 

5 41 41 79 79 

6 43 43 79 79 

7 44 45 79 79 

8 43 44 80 80 

9 44 44 80 80 

10 44 44 80 80 

11 44 45 80 80 

12 45 45 80 80 

13 45 45 79 79 

14 42 41 79 79 

15 42 41 79 79 

16 41 41 80 80 

17 40 40 80 80 

18 40 40 80 80 

19 40 41 81 81 

20 41 41 81 81 

21 42 42 81 81 

22 42 42 81 81 

23 42 42 81 81 

24 43 43 81 81 

High Average 

Reading Ref Deviation 

212 212 0.67 

212 212 0.00 

212 212 0.67 

212 212 0.00 

212 212 0.00 

212 212 0.00 

212 212 0.33 

212 212 0.33 

212 212 0.00 

212 213 0.33 

212 213 0.67 

212 212 0.00 

212 212 0.00 

212 212 0.33 

212 212 0.33 

212 212 0.00 

212 212 0.00 

212 213 0.33 

212 212 0.33 

212 212 0.00 

212 212 0:00 

212 212 0.00 

212 212 0.00 

212 212 0.00 

~ Envisage 

- 

Environmental 

Incorporated 

-

P.O. Box 152 RlohfielC, Ohio 44286 

Phone (216) 526-0990 

GRASEBYa 32 

A1VDERSEN 

CONTROL UNIT CALIBRATION 

(Englisn Units) 

Date 9 "'7 ` 5.3 Metering System 

Identif ication: _5'9 3 - 79s 

Barometric pressure, Pb= 09"-35 in. Hg Model Number SO -8'DO 

Orifice 

manometer 

setting 

A H 

in. H20 

Spirometer 

(wet meter) 

gas volume 

Vw 

ft 3 

Dry gas 

meter 

volume 

Vm 

ft 3 

Tem eratures 

Time 

0 

min 

Spirometer 

(wet meter) 

tw 

° F 

Drv Gas Meter 

Inlet 

t i 

° F 

Outlet 

to 

° F 

Average 

tm 

° F 

1.0 5 y, l93 

2.0 5 ; i B'-17' 7S,70 /z/ ~''Z. v~..s G, 3--3 

4.0 S .S' /yS 7G, f l zs 5r5i 011,.s .SC7 

Calculations 

AH 

in. H20 

Y AH@ 

yw Pb (tm + 460) 2 

0.0317 0 H (tw + 460) 0 

Pb(to + 460 ) vw 

vm [pb + 13 6 ~ (t

w+ 460) 

1.0 ),76 

2.0 

4.0 

Average 

Y = Ratio of reading of wet test meter to dry test meter; toferance 

for individual values f0.02 from average. 

AH@ = Orifice pressure differential that equates to 0.75 cfm of air 

@ 68 ° F and 29.92 inches of inercury, in. H2O; tolerance 

for individuai values ±0.20 from average. 

GRASEBY ANOERSEN 

4801 rULTON INOUSTRUL BLVO. ATLANTA, GA 30336-2003. USA 

Calibrated by: TEL 404 691 1910 rAX: 404 691 6315 

Toll frse: 800 141 6898 

"3 7 
33 

EMISSION SAMPLING 

NOMENCLATURE 

~ Envisage 

Environmental 

- Incorporated 

_ P.O. Box 152 Riohlleld. Ohio 44266 

Phone (216) 526-0990 

2~'' 
SA1/iPLI~+G ~OyCEi`ICLATLIRE - 34 

A = C:oss section:: area of stac.11C or duct, fr.'-. 

Aa = C:oss secuenai area of nozzle entry plane, ft. = . 

Bws = Water vapor i.n zas stream:, proportion by volume. 

C = Nomosraph ccrrection fac:or, dimensionless. 

CS = Concentrat:en of particulate matter in aas stream, dry basis-corrected to 

standard conditions, gr/dsc: v 

Da = Nominal di,a:ueter of probe nozze entry plane, in. 

E = Particulate Emission Rate, 1b./hr. 

"H = Ave.aae pressu_re diffzrential across orince, i.n. of I-LO. 

,"H,a = Orince meter, calibration factor, in. of H.O. 

I = Percent of isoldnetic samplin;, %. 

Kp = Pitot tube constant, 85.T9 ft./sec. 

lY1a = Molecular weiaht of gas, drv basis, lb./lb.-mole. 

Total amount of partiealate matter collected, g. 

Nis = Molecular weia-ht of oas, wet basis, Ib./Ib: mole. 

N,„ = Molecular weight of water, 18 Ib./lb.-mole. 

pbar = Barometric press•sre, in. of Hv. 

pg = Pressure diiferential from aas stream to atmosphere, 

(static pressure) in. of H2O. 

ps = Absolute gas stream pressure,(P b~ + Pe/13.6) in. of H. 

pstd = Absolute pressure at standard conditions, 29.92 in. of H. 

pw. = Density of water, 0.0022 lb./ml. ~ Envlsage 

_ 

Environmental Incorporated 

. ~

P.O. Box 152 Richlield. Ohio 44266 

Phone (216) 526-0990 - 
35 

SA~- iPLNG N0MEyCLaTL-RE - continued 

"p = Average of ti:e sqL are roots of the velocit,i head readings, i-- of H2O. 

Q = Volt:re,c dow rate at sas stre conditions, A.C.F.M. 

Q ~ t~ = Dry voiumeti:c gas tlo ~v rate corr......,Q to standard conditio ~, D.S.C.F.I~ i. 

R = Ideal zas constant, 21.5 ~ in. of F:;fr/ °R-ib.-mole. .. , 

t = Total sampling time, minutes. 

Tm = Average dry gas meter temperature, °R. 

TS = Average absolute aas stream temperar.:re, °R. 

Tstd = Standard absolute temperature, 528 °ranldne. 

VtC = Volume of water collected in i.mpingers and silica oel, mI. 

Vm = Volume of gas sample measured at meter box (meter condit:ons), ft.'. 

Vm(std) = Voiume of gas sample measured at meter box (corrected to standard 

coIIdltlon5), ft. 3 . 

Vs = Average gas stream velocity, ft./sec. 

Volume of water vapor in gas sample (standard conditions), ft.'. 

13.6 = Specific gravity of inercury (H.>. 

°1oCO3 = Percent by volume of CO, in gas stream (dry basis). 

%'o0:= Percent by volume of 0, in gas stream (dry basis). 

%aC0 = Percent by volume of CO in gas stream (dry basis). 

qaN:= Percent by volume of N2 in gas stream (dry basis). 

~ Envisage 

Envlronmental 

- Incorporated 

_P.O. 8ox 152 RlOhfleltl. OhiO 44286 

Phone (216) 526-0980 
36 

EMISSION SAMPLING 

CALCULATIONS 

- Envisage 

Environmental 

- Incorporated 

-

P.O. Box 152 fiiChllBltl. OhiO 44286 

Phone (216) 526-0990 
1) Volume - of- dry - gas - sampled - through - meter - box - at - standard - conditions, 

_^H_ 

V = V _ T_std Pb + ---

--_13.6___ 

m(std) m 

Tm Pstd 

(EPA Equation 5-1) 

Where: 

Vm(std)- Volume of gas sample mea5ured at meter box (corrected to 

standard conditions), ft . 

Vm = Volume of gas simple measured at meter box (meter 

condi-tions), ft . 

Tstd = Standard absolute temperature, 528 0 Rankine. 

Tm = Average dry gas meter temperature, o R. 

Pbar = 

Barometric Pressure, in. Hg. 

^H = Average pressure differential across orifice, in. H 2 O. 

13.6 = Specific gravity of inercury (Hg). 

Pstd = 

Absolute pressure at standard conditions, 29.92 in. Hg. 

Example: Run 1 

V = 45.06 ft3 

m 

T = 532.1 o R 

m 

^H = 1.55 in. H2 0 

Pbar = 

28•78 in. Hg 

528.0 28.78 + 

-1.55-- 

V 45.06 ------- ---------------- 13 = 6 - m(std) 532.1 29.92 

= 45.06 ( 0.9922 ) ( 0.9657 ) 

= 43.18 ft3 

_ Envlsage 

~ 

Envlronmental 

_

Incorporated 

P.O. 8ox 152 Richlield, Ohio 44266 

Phone (216) 526-0990 

37 
38 2) Volume 

-

of 

-

water 

-

vapor 

-

collected 

-

at 

-

standard 

-

conditions, 

----------------------------------------------- 

P 

w 

Vw(std)= Vlc -- M --- 

w 

( R ) ( T std ) 

P std 

(EPA Equation 5-2) 

Where: 

Vw(std) Volume of water vapor in gas sample (standard conditions) ft 3 . 

Vlc = Volume of water collected in impingers & silica gel, ml. 

Pw = Density of water, 0.0022 lb/ml. 

M w = Molecular weight of water, 18 lb/lb-mole. 

R = Ideal gas constant, 21.85 in. Hg-ft 3/ °R-lb-mole. 

Tstd = 

Standard absolute temperature, 528 ° Rankine. 

Pstd = 

Absolute pressure at standard conditions, 29.92 in. Hg. 

Example: Run 1 

V lc = 60.6 ml 

V 

I 60.6 0_0022 -I I( 21.85 ) ( 528.0 )- 

w(std)= - 18.0 - - ------- 29.92-------- - 

= 2.85 ft3 

~ Envlsage 

Environmental 

- Incorporated 

-

P.O. Box 152 Rlchiield. Ohio 44286 

Phone (216) 526-0990 

7 

40 

4) Dry 

-

Molecular 

-

Weight 

-

of 

-

gas 

-

in 

-

gas 

-

stream, 

---------------------------------- 

Md = 0.440 (%CO2 ) + 0.320 (%A2 ) + 0.280 (%N 2+ %CO) 

(EPA Equation 3-2) 

Where: 

Md = Molecular weight of gas, dry basis, lb/lb-mole. 

0.440 = Molecular weight of CO2 divided by 100. 

0.320 = Molecular weight of 02divided by 100. 

0.280 = Molecular weight of N2or CO (same for both compounds) 

divided by 100. 

% CO2 = Percent by volume of CO2 in gas stream (dry basis). 

% 02 = Percent by volume of 02 in gas stream (dry basis). 

% CO = Percent by volume of CO in gas stream (dry basis). 

% N2 = Percent by volume of N2 in gas stream (dry basis). 

Example: Run 1 

% CO2= 8.4 

% 02 = 16.5 

% CO = 0.0 

9'o N 2 = 75.1 

Md = 0.440 ( 8.4 ) + 0.320 ( 16.5 ) + 0.280 ( 75.1 ) 

= 3.696 + 5.280 + 21.028 

= 30.00 lb/lb-mole 

~ Envlsage 

Environmental 

_

- Incorporated 

P.O. Box 152 RlthtlelG, Ohio 44266 

Phone (216) 526-0990 

6) Average 42 

-

Gas 

-

Stream 

-

Velocity, 

------------------------ 

V= 

s 

T 

K C ^P - - s -- 

P P av9 P sMs 

\ (EPA Equation 2-9) 

Average gas stream velocity, ft/sec. 

_(1_b_/lb-mole)_(in_.H_g__) ~ Pitot tube constant, 85.49 ft 

- sec I - ( o R}(in.H 0) 

I'Z 

2 - 

Pitot tube coefficient, dimensionless. 

Average of th square roots of the velocity head 

readings, ( \~^p ) ( in.H 2 O ). 

Average absolute gas stream temperature, oR. 

Absolute gas stream pressure,(Pbar + Pg/13.6) in.Hg. 

Barometric Pressure, in. Hg. 

Pressure differential from gas stream to atmosphere, 

(static pressure) in.H 2O. 

Molecular weight of gas, wet basis, lb/lb-mole. 

Where: 

V s = 

Kp = 

C = 

P 

APavg 

Ts = 

P s 

Pbar 

Pg = 

Ms = 

Example: Run 1 

C = 

P 

APavg 

T = 

s 

Ps 

Ms = 

0.84 

0.134 in.H2O

1/2 

721.5 oR 

Pbar + Pg/13.6 = 28.78 + 

29.26 lb/lb-mole 

-0.02 /13.6 = 28.78 in.Hg 

------------------------- 

Vs = ( 85.49 )( 0.84 ) ( 0.134 ) 28.78 

-721_5_-

\ ( ) ( 29.26 ) 

8.91 ft/sec 

~ Envisage 

Environmental 

- Incorporated 

-

P.O. Boz 152 faichflelC. Ohio 44266 

Phone (216) 526-0990 

8)' Volumetric 44 

-

Flow 

-

Rate 

-

at 

-

Standard 

-

Conditions, 

-------------------------------------- 

Q = 60 ( 1- B ) V A _ Tstd - - - 

 

-- P s_ - 

 - 

sd ws s Ts Pstd 

Where: (EPA Equation 2-10) 

Qsd = Dry volumetric gas flow rate corrected to standard 

conditions, S.C.F.M. 

60 = Conversion factor from seconds to minutes. 

Bws = Water vapor in gas stream, proportion by volume. 

Vs = Average gas stream velocity, ft/sec. 

A = Cross sectional area of stack or duct, ft 2 . 

T std = 

Standard absolute temperature, 528 ° Rankine. 

Ts = Average absolute gas stream temperature, ° R. 

P s = Absolute gas stream pressure,(Pbar + Pg/13.6) in.Hg. 

Pbar = 

Barometric Pressure, in. Hg. 

Pg = Pressure differential from gas stream to atmosphere, 

(static pressure) in.H 2 O. 

P std = 

Absolute pressure at standard conditions, 29.92 in. Hg. 

Example: Run 1 

B = 0.0620 

ws 

Vs = 8.91 ft/sec 

A = 19.63 ft2 

T = 721.5 °R 

s 

Ps Pbar + Pg/13.6 = 28.78 + -0.02 /13.6 = 28.78 in.Hg 

Q = 60 ( 1 - 0.0620 ) ( 8.91 ) ( 19.63 ) _528_0 28_78 - 

sd 721.5 29.92 

= 6,929 SCFM 

~ Envisage 

Environmental 

_ Inoorporated 

-

P.O. Boz 152 Richlieltl. Ohio 44286 

Phone (216) 526-0990 

I Pi 
45 

9) Gas 

-

Stream 

-

Particulate 

-

Concentration, 

--------------------------------- 

M 

C s = 15.43 gr./g - ~ --n---- 

m(std) 

(EPA Equation 5-6) 

Where: 

C s = Concentration of particulate matter in gas stream, dry 

basis-corrected to standard conditions, gr/dscf. 

Mn = Total amount of particulate matter collected in probe wash 

and on filter, g. 

Vm(std) Volume of gas sample mea5ured at meter box (corrected to 

standard conditions), ft . 

Example: Run 1 

Mn = 0.0425 g 

Vm(std) 43.18 ft3 

C I 15.43 0.0425 s = 43.18 

= 0.0152 gr/dscf 

~ Envlsage 

Environmental 

- Incorporated 

-

P.O. Box 152 Rlohlield, Ohio 44266 

Phone(216)526-0990 
10) Particulate 

-

Emission 

-

Rate, 

----------------------- 

46 

_ _ 1 _pound _ _6_0_ _m_inute_s__ 

E Q sd C s I 7000 grains I I 1 hour 

Where: 

E = Particulate Emission Rate, lb/hr. 

Rsd = Dry volumetric gas flow rate corrected to standard 

conditions, S.C.F.M. 

C s = Concentration of particulate matter in gas stream, dry 

basis-corrected to standard conditions, gr/dscf. 

Example: Run 1 

Q sd 

C s = 

E _ ( 

6,929 ft3 

0.0152. gr/dscf 

6,929 ) ( 0.0152 ) _60 

7000_ 

0.90 lb/hr 

- Envlsage 

Environmental 

- Inoorporated 

-

P.O. Box 152 RlChlleltl, OhiO 44266 

Phone (216) 526-0990 

I 

7 
11) Percent - of - Isokinetic Sampling, 47 

100 T K V + -Vm- P +---H - 

A 

I _ s 3 lc Tm bar 13.6 

----------- ---------- 60 --- A ---- ~ ---- P ----t-------(EPA 

Where: n s s Equation 5-7 

I = Percent of Isokinetic sampling, %. 

Ts = Average absolute gas stream temperature, ° R. 

K3 = Constant, 0.002669 in.Hg-ft 3/ml- °R. 

Vlc = Volume of water collected in impingers & silica gel, ml. 

Vm = Gas sample volume measured at meter box (meter conditions), ft 3 . 

Tm = Average dry gas meter temperature, °R. 

P bar = 

Barometric Pressure, in. Hg. 

^H = Average pressure differential across orifice, in. H2 0. 

t = Total sampling time, minutes. 

V s = Average gas stream velocity, ft/sec'. 

Ps = Absolute gas stream pressure, in.Hg. 

Dn = Nominal diameter of probe nozzle tip, inches. 

An = Cross sectional area of nozzle, ft 2 . 

Example: Run 1 

Ts = 721.5 ° R ^H = 1.55 in.H2O 

Vlc = 60.6 ml t = 60.0 min. 

Vm = 45.06 ft3 Vs = 8.91 ft/sec 

Tm = 532.1 ° R P s = 28.78 in.Hg 

An = 0.0020294 ft2 Pbar = 

28•78 in.Hg 

I _ 721.5 ( 100 ) 0.002669 ( 60.6 )+ 

I_ --532

45.06 

1 _I I_ 

28'78 + 1356 

_ I ------- 60 (0.0020294 - ) ---- ( --- 8.91 -- ) --- ( -- 28.78 -- ) --- ( --- 50.0 -- ) ---------_-- 

= 100.5 % 

- Envisage 

Environmental 

- Incorporated 

_P.O. Box 152 Fichlield. Ohio 44286 

Phone (218) 526-0990 

Fo7 
48 

9) Gas 

-

Stream 

-

NOx 

-

Concentration, 

---------------------------- 

- MW---- -- 1 - Pound--- 

C = --ppm-- I =----M= ~ =---= I--- I = 453_59-grams j nox - ------ 

106 

Where: 

C

nox = Concentration of Nitrogen Oxides (as NO2) in gas 

stream, dry basis at standard conditions, 1b/dscf. 

ppm = Average concentration of NOx .as measured at detector 

MW = Molecular Weight of Compound used for comparison 

and/or instrument calibrarion, g/g-mole. 

M.V. = Volume occupied by one mole of gas at standa5d conditions 

of 680 Fahrenheit and 29.92" Hg, 0.849531 ft /mole. 

Example: Run 1 

PPM = 51.8 ppm 

MW = 46.010 g 

51.8 46.010 1 Pou_nd 

C = LO.84953i

nox -------------------------- --------------------- 

106 

=6.185 x 10 6 1b/dscf 

~ Envlsage 

Environmentai 

- Incorporated 

-

P.O. Boa 152 Riohlleld. Ohio 44286 

Phone (216) 526-0990 

50 

CHART RECORDINGS 

~ Envisage 

~ 

Environmental 

_

Incorporated 

P.O. BOZ 152 RiChliBlO, OhiO 44286 

Phone (216) 526-0990 
~ 

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ML 
1 

STACK TEST 

OBSERVATION REPORT ' 

METROPOLITAN INDUSTRIES 

15 76 05 1149 P006 

NOVEMBER 17 & 18, 1993 

On the above date, I arrived at Metropolitan Industries, located at 1201 Millerton Rd. SE on the outskirts 

of Canton, to observe a stack test on a new 150' stainless steel stack for P006. This source is the #3 

tunnel kiln for the tile "firing". At that time, the #3 tunnel kiln was the only kiln connected to the stack. 

The #1  kilns are scheduled to be connected to the stack some time in December of 1993. The 

ductwork is run to the current #1  kiln emission stacks, but the final connections have not been 

made. These ductwork extensions were sealed off from the outside air (at this time since not connected) 

by valves installed for such a purpose as to isolate each kiln exhaust, if necessary. These valves were 

in the closed position during all testing. The testing was to be done by Envisage Environmental Inc. The 

weather on November 17, was cold and rainy. In fact, tornado warnings were issued for Stark County. 

Because of the conditions, it was determined to postpone the particulate and Hf portion of the test, and 

to run only that for SO2, NO,, and CO. The rest of the parameters would be done on the 18 1. My 

contacts were Mr. Philip McGuinness of Metropolitan, and Eric Hevener & James Gray of Envisage on 

the 17'~ , and Greg Sinkovich of Envisage on the 18 ~. My job was to observe the test runs and to conduct 

VE observations utilizing Method 9. 

The information obtained from Philip McG. concerned the P006 source. The maximum temperature in 

y~ the peak compartment was running at 1150°C. The feed rate was set at 90% capacity (36 cars per day). 

That is 40 minutes per car. Each car contained 1.848 Tons of tile products. At 90% capacity, that is 

66.528 T/D: 100% would be 73.92 T/D These tiles were of the same consistency for the entire test - 

40% clay and 60% shale. This particular mixture is called a"250" mix. Tile samples were collected 

-by Philip McG. to correspond to the SOZtesting. Such tiles were collected ahead of time to correspond 

~ to the cars. Once it was calculated which cars were in what position at a particular time during the 

testing, those tile samples were pulled for composite testing. (At the current time, all composite sample 

tests are run by Stark Ceramics with intermittent sample checks done by NSL for cross checking. I 

receiv a year to date pr ~int out of all the composite sampling that has been done, and the results of the 

tests. See the attached printout.) Philip McG. also informed me that Envisage was asked by 

Metropolitan to include two more parameters in their testing, just to document that Metropolitan does not 

have a problem with them. Those two parameters are VOC and Pb. The VOC was to be run with the 

other gases, and the Pb would be tested for by a separate sampling train at the time of the Particulate and 

Hf testing. While talking with Philip McG., he informed me (when he saw the P006 copy of PTI 

conditions and STC's I had with me) that there as a typo_and mistake made, and of which Dan Schiltz, 

of our office, had already submitted a modi

f

fication to OEPA for. n page 4 of Application No. 15-883, 

14.25 ]bs S02/yr should read *52.77 lbs S02/hr or 19.26 lbs SOZ/hr. The * was to denote combined 

emissions from P004, P005 and P006. 

My observations on the 171consisted of watching only one run on the gas sampling end of the test. 

VOC, NOx , SOZ and CO were all checked by utilizing CEM's (continuous emission monitors). The SO Z 

and CO used strip charts for recording results. The VOC and NO xrecordings were done by hand, every 

minute. I observed the equipment being calibrated using EPA Protocol I gases. Each run was conducted 

for one hour, with the standardized gases being run after each run to verify the results. Since I only 

observed the first run, I can only account for what I saw during that time period. Everything appeared 

scientifically correct, to my knowledge, with the exception of what I observed concerning the S0 2CEM 

operation. It appeared that this unit was sensitive to pressure flow of gas through the unit. This is 

L~p ( 
STACK TEST 

OBSERVATION REPORT 

METROPOLITAN INDUSTRIES 

15 76 05 1149 P006 

NOVEMBER 17 & 18, 1993 

PAGE 2 

understandable, and it appeared that all precautions were taken as to control the amount of gas flowing 

through the unit. All gas samples were feed pumped into a glass manifold which had an excess flow port 

at the end. A line was run from this manifold to the SOZCEM and another pump was installed after the 

CEM in order to pull the sample through the machine at a steady rate. This setup appeared fine. 

However, what did not make sense was that the CEM indicated that the standard SO Zsample readings 

could be altered by changing the Protocol 1 gas tank regulator setting.(?) As the pressure increased, the 

concentration increased. After working with the unit to initially calibrate it, the sampling was done and 

then the standards run through the unit again. However, the regulator was moved in the process of 

checking the standards instead of leaving it set as it was during the calibration process. In my own 

personal opinion, this should invalidate the test for S0 2. The following information is what I recorded 

concerning the standard checks and a quick, visual average of the readings (in ppm) during the stack 

testing: 

POLLUTANT AVER. TEST RDG. STD. ,/ STD. ✓ STD. ~ 

CO = 4 702 704 200 192 97.1 83 

S02 = 22 827 815 447.7 ? 

NOx = 60 88.1 89 49.48 48.5 

VOC =10 800 750 56 .= 50 

Results will have to be looked at in. order to make a final determination. 

My observations on the 18th consisted of doing VE readings on the emissions from the 150' stack while 

the P006 source was operating at 90% capacity. All dampers were observed being checked to assure they 

were closed. This test period was to determine particulate, Hf and Pb emission levels, if any. During 

this testing period, Envisage appeared to have some problems with getting a correct stack temperature 

and flow rate. Originally, their instruments showed no flow velocity and a stack temperature of about 

150_ °F Metropolitan checked their stack exhaust temperature at the source and indicated that they were 

emitting exhaust about 300°F. Without Metropolitan making any adjustments, Envisage kept working 

and eventually established ck tem erature of about 256°F and a op (velocity indicator) of .02" 

(HZO). This made sense because the source (P006) is a long way from the stack (about 264'). Before 

starting, the temperature and velocity were lost again, but Greg Sinkovich was able to re-establish 

readings. The first two runs were done during periods in which the background for the VE's was a 

grayish sky. By the third run, the sky had cleared to a blue background. It is assumed that the readings 

during the third run are more representative of the emissions from the source. Especially since a 

continuous flow of emissions could be detected while standing directly below the stack before and 

between the first two runs-ELeak check observations could not be made by myself because all equipment 

was on the stack platform, about 75' above the ground, and in which a safety harness was essential in 

order to climb the stack ladder]Other than the noted problems, everything else appeared to be o.k. 

ick L. Miller 

Staff Field Inspector 

m 
EtvflSSit~N C~ATA FOFt C:UMFLIAiVC:F T FST 1 i ~ i 7Jy3 t~ 7111 9193 TK4 ~ 

PRODUCTION CLAYJSHALE SAMPLES FOR SULFUR DETERMINATION 

CAR #'s FROM END OF ZONE 8 TO ST ART OF 20NE 2 

TEST 1 48,194,183,5,152,30,105,73,173,91,41,9,20,82,21. 

TEST 2 5,152.30.105.73,173,91,41,9,20.82,21,81,83,4,130. 

TEST 3 152,30,105,73,173,91,41,9,20,82,21,81,83,4,130,107. 

SAMPLES TO NSL SAMPLES TO STARK AVERAGE 

% SULFUR % SULFUR % SULFUR 

TEST 1 0.059 TEST 1 A 0.076 

e 0.072 0.069 

TEST 2 0.055 TEST 2 A 0.068 

s 0.07 0.06433 

TEST 3 0.04 TEST 3 A 0.06 

® 0.076 0.05867 

2 
EPACST.XLS 

!:CAFtBi<7ttE.`AND: :gtll.FU ~t 'T~S~fNG ' 

DAtLY CLAY/SHALE SAMPLES OF 10gms TOTAL COLLECTED TO 

REPRESENT THE DAYS PROIaUCTION COLOR. ACCUMULATED 

FOR A 7 DAY PERiOD, TO GIVE A COMPOSITE SAMPLE FOR 

TESTING AT STARK CERAMICS FOR CARBON AND SULFUR CONTENT 

;;M(1:0~k :,MONTHLY AVERAGE SULFUR % NOT TO EXCEED 0.1 ~S.:ticni. 

E.G. 310 PRODUCTfON COLOR (70% SHALE. 30°la CLAY ) REPRESENTED 

BY 7gms SHALE AND 3gms CLAY 

1LiU TAverage Dt+} Tc~ns; 

Y' f~#Tr,t~ T0TAl. i 

~Tor~ sOc~ Ki.in/day.1 /kiin/daya 

s5 i 2,2 , 77 fi ; ;6 

35 j 2.2 77 64.68 ; 

35 2.2 77 64.68 ; 

35 2.2 ' 77 i 64.68 ! 

35 2.2 77 ! 64.68 , 

35 2.2 77 64.68 j 

35 2.2 77 64.68 ' 

35 2.2 77 ( 64.68 ; 

3.4.931 2.2 73 1 61.512 ! 

.., ...... ,... . =_ 

; ATES L ~ GiL~]i~S 

12,/$0:.,1/ 1C1507,67x ; 0.21 0.126 ; 0M6 I 

_; 1/11...1 /17 57x,105 ; I 0.229 { 0.136 j 0.365 

: 1/ 18...1 /24 105,107 ? 70.233 1 0.134 1 0.367 

'El25 ... 1/31 105007308250± 0.219 i 0.212 1 0.431 0_152 

2/1 ... 2i7 1250,350 #3 Blay ' 0.241 0.052 ; 0.293 

: 218 ... 2/14 1310 ; 0.241 0.188 ! 0.429 

21 i 5. ..2/21 310, 31 X 0.277 ! 0.11 1 0.387 

' 2/22...2/28131 X,507 ; 0.151 0.104 ; 0.255 0.10 

`3/1 ... 3/7 1507, i ! 0.22 ! 0.082 0.302 

3/8 ... 3/14 1507,101.57X _! 1 0.293 i 0.136 ; 0.429 

. 3l15...3/21 i57X,15X j 0.266 j 0.092 ' 0.358 ; 351 2 

; 3122. ..3/28 j 15X,105 I ' 0.241 j 0.09 ! 0.327 32-3.28.8 2.2 

3/29 ... 4/4 ! 310 1 0.147 '; 0.176 ! 0.323 0.1144 32 1 2.2 

4/5 ... 4/1 1 j310.31X + FL j 0.223 j 0.068 ! 0.291 32 2.2 

. 4/12...4/18 , 31X.505 i i 0.226 j 0.124 0.35 32 2.2 

; 4/19 ... 4/25 1505,107 0.289 { 0.208 j 0.497 1 32 2.2 

4/2~-v ... 5/2 1107,308,250 ; Sad/Brki 0.223 { 0.14 ; 0.3631 0.135 , 32 2.2 

`5/3 ... 5/9 1250,105. ! { 0.272 1).17810.13 0.45 32 1 2.2 

`5110...5/16 105,507 ; 0 368 p.182 0.1 ~ ~.55 ~ 32 2.2 

' S/17...5/23, 507.57X ; I 0.285 V23810.19 0.523 32 2.2 

`5/24.757/30! 57X.310 ; ' 0.285 p.196 0.1 q .481 P. 19810.11 32 1 2.2 

: 5/31 ... 616 ; 310 ! ; 0.118 I 0.078 j 0.196 35-6.1.9 2.2 

6/7 ... 6/13 1310.31 X jS of cfays1 0.227 i 0.086 ! 0.313 j 35 i 2.2 

E/14 ... 6/20 , 31X,109 I 0.159 i 0.078 I 0.237 ; I 35 I 2.2 

. 6121...6/27 ? 109.240,107 I 0.245 i 0.12 ; 0.365 j 0.0905 35 i 2.2 

; 6128...7/4 ; 507 ; 0.166 1 0.188 i 0.354 ! I 35 i 2.2 

7/5 ... 71 1 1 j 507.57X ! I 0.191 { 0.132 ! 0.323 39-7.7.93 2.2 

. 7/12...7/18 i 57X ; i 0.234 0.09 I 0. ~ 40-7.13.912.2 

' 7/19...7/25 !; 57X.105 'New Nort0.288 j 0.314 ! 0.602 F40 1 2.2 

7!25 ... 8/1 1240.250. No grog! 0.178 I 0.099 ! 0.277 1 0.16461 40 { 2.2 

8/2...8/8 308,310 ; 0.248 ~ 0.105 ~ 0.353 j 38-8.2.9$ 2 

8/9. ..8/ 7 5 1310 I 0.13 i 0.01 ; 0.14 40-8.5.9$ 2.2 

8116...8122;310,350,31X ;31X MIXi 0.181 ! 0.058 j 0.239 ; 40 ; 2.2 

To date Averagel 0.1293 jM/LOtiN 0.1317 

ALL FIGS M/HIGt= 0.1357 

av of avs 

" SAMPLES SENT TO NSL FOR CROSS CHECKS 

70 

70 

70 

77 

77 

77 

77 

77 

15.1 

88 

88 
ENAC:ST.XLS 

DAILY CLAY/SHALE SAMPLES OF 10gms TOTAL COLLECTED TO 

REPRESENT THE DAYS PRODUCTION COLOR, ACCUMULATED 

FOR A 7 DAY PERIOD. TO GI\fE A COMPOSITE SAMPLE FOR 

TESTING AT STARK CERAMICS FOR CARBON AND SULFUR CONTENT 

E.G. 310 PRODUCTION COLOR (70% St-lALE, 30% CLAY ) REPRESENTED 

BY 7gms SHALE AND 3gms CLAY 

ci~adu~ . ...:.: .... .:..... ~.... 

iJ:AL.ra~~. 

<;:.'W~~:::: ::•::. ...:........_ 

, a:_ r. ~ 

,etTory=>:TE~Tf~:, .................M ~ .:.... ~ .:.. ~ .. ~ .:., i 

Ki(rifday i ~ilnfciay:i 

$8 2.2 1 8$.6 , 70.224 ; 

37 2.2 81.4 68.376 1 

38-9.6.931 2.2 83.6 I 70.224 ': 

39-40 2.2 85.8 1 72.072 ! 

40 2.2 88 73.92 ; 

I 38-40 2.2 88 ! 73.92 ; 

40-38 2.2 88 ; 73.92 

i 0 I 2.2 88 I 73.92 ; 

4G ;, 2.2 ; 89 ; 78.92 i 

40 ► 2.2 88 i 73.92 ! 

i 35 i 2.2 77 i 64.68 ; 

I 36 f 2.2 ; 79.2 ; 71.28 ; 

I , I Q 1 Q 

! f o 0 

0 0 

i 0 0 

o ; 0 

0 0 

~4 k.OR~ . i ~ ~ 

 , !Q

~ '.~' • ''.T It7 ... 

. df `... 

; a(23 ... 8/29 i 31X.310,101 ; SMPL "B"; 0.171 i 0.07 10.241 0.0608 

? 8;3o ... 9l5 i101,BISCa ~ SMPL "B"' 0.266 ; 0.17£ ! 0.4$4 1 

916 ... 9/12 , 507c1ay grog ; SMPL "B"I 0.21 0.182 , 0.392 

9113...9119 1507,57X !SMPL "B"j 0.243 1 0.13 1 0.373 

9/20 ... 9126 57X 0.186 1 0.568 

; 9/27 ... 10J3 , 57X . 107. 310 i 310 80:20 i 0.231 I. 0.168 0.405 0.1688 

;10/4 ... 10/ 101 310 0.157 I, 0.048 0.205 

10/11 ... 1011 ~ 310,31X labtstcly ! 0.116 i 0.044 i 0.16 

1 CJ1$...10/201X.105 ::?rodt=to!y l 0:202 1 0.134 ~ 0.336 1 

12Ii 3 ... 12/19 

i 2/20...12126 

To data Avorageq 0.1287 ;MILtOW 0.128 

ALL FIGS MIHIGH 0.1311 

av cf avs 

. .. 

; YE}4R A1lEt~.ACE. S~ 

.~~~. ~` :7771 

t SAMPLES SENT TO NSL FOR CROSS CHECKS 

SCHEDULE OF 40 c.p.d thru'put 73.92 tons/day 2.2 tons wvorage loar'0.^04(-1B% for rnoisture ccrter,!) 

0.1287% S IS EOUAL TO 69.4486 TONS S02/KILNIYEAR 

0.1311 % S IS EQUAL TO 70.7437 TONS SO?JKILNlYEAR 

/ 

~v 
Date: 

Observ. 

Faci i i ty 

Source: 

Test Fir, 

. • • . ~ ~ ~`~ iC;-. G ~ c~e~, er- 

~ 

' ~li/!r'~j• ~~jX 

t"tl-.0 , 

~ 

Particulate Sampling - Observation Checklist 

Samplin~9' Method (s) : 

FM 5 G'~ ; ~A 3; ~ B 13; 5D C3; 5E C3; 5F E3; 8 13; 12 E3; 17 E3; 

or other t~t If other, please describe. ) /- S~ (o ~ 7t /a v1;3A 

- --~ 

+;re there any/~ ~ odi f i cati ons to the speci f i ed ref erence +nethod ( s)? 

Yes t3; No M(If yes, please describe modificatien.) 

Do the inlet (if applicable) and outlet sampling lc3`cations meet 

the re,q,U irements specified in RM 1? 

YQs 0; No 13 (If no, how was (were) the locatien(s) modified to 

allow =_ampling?) 

If inlet/outlet sampling is being 

beina taken simultaneously"?h/,4 

Yes 13; No 13 (If nb. be sure that 

parameters are the same when they 

performed, are the samples 

the =_ource operatinq 

=witch r'rom one to th e other.) 

If cvclonic flow is present and other . sampl i ng ~ ~ locati ons do not' 

exist, how will the samples be withdrawn? 1C4 

Di recti onal probe techni que E3; Alignment technique E3; other E3 

(If other, please describe.) 

Is the sampling train set up properly, in accordance with the 

refer e/ce method or as agreed upon in the pre-test meeting? 

Yes M: No E3 (If no, correct problems and continue, if 

possible. ) 

Check to ensure that the sampling equipment has b.een recently 

calibrated (i . e. , )feter bo::, thermometers/thermocouples,. pitot 

tubes, etc. ) OM; C''f, not OK C 3 

Type of f i 1 t er : ~xSS 

Is th filter assembly positioned properly? 

Yes I: No 13 (If no, adjust and continue, if possible. Please 

note that the Ti'lter may be chanaed during the test run; however, 

it is recommended that the .entire filter assembly be chanaed. ) 

ME 
- . . ~ ~ z ~✓ 

. . 7 D 2 7o 11 -_Z.o 0 ! S,2 f 7, / ~3 

• jo~ LA2 P-z 7 Vy7. 7 

~vvx ~. 6 ~ • ~~ ; ~ ~' y ~' s~~ y~'.,~ 

✓~~ ~- t.! LS ~ ( 

is less. If "the samplinq 

; r ~ ~t'rre ~~ 

"r'sl ~ 1 f

ie

`icfi.~ ~a~ ~~u is. rss:,4 

was stopped dur'nq the test run to 

change a sampling train component, be sure the sampling train is 

leaE:-checked again. ) 

Feriodically record readings from the test firm's raw data 

sheet(s) (i.e., delta fi, delta P, initiai qas volume, filter 

numbers, filter box temperatures, etc.). Or photocopies of the 

raw data sheets may be requested from the test firm. (Attach the 

readings and/or photocopies to this checl:list. ) 

Checi; to ensure that the sample train recovery procedures are 

conducted properly (i.e., filter handling, probe wash, liquid 

transfers, appropriate sample recovery solution(s), recovery of 

nozzel catch, etc.): 

Will there be additional sampling and/or analyses performed 

(i.e., particle size distributions, bacl;-half analysis, HC1 

analys/ s, metal s anal ysi s, etc. )? 

Y70 C No E3 (If yes, please describe. ) (/~ ~~k~~ c~~.r (6L sG; 

^~ C ) A) oX~ o 

C<! /// -A--1 ~ 

re'.ri.. 1-4 ej~- -.iZ,.. ~- ~- ~wn 0 C.7 t; .t E - 

Optional checE:s/verifications: 

The test firm may be asked to do a ten (10) minute run on their 

dry gas meter for calibration verification. Operate the meter at 

the delta H setting obtained from the test firm's calibration 

sl-heet. Record the volume collected, the dry gas meter 

temperature and the barometric pressure. Calculate a dry gas 

meter calibration checF: value, Yc, as follows: 

Yc = 10 10.0319 * TmJ 1/2 

Vm Fbar 

Where: 

Yc = dry gas meter calibration check value (dimensionless) 

10 = ten minute verification run 

Compare the Yc value with the dry gas meter calibration factor Y 

to determine that: 0.97 Y< Yc < 1.03 Y. If the Yc value is not 

within this range the meter should be recalibrated and if 

completed the run and/or test should be voided. 

The test firm may be required to perform at least one actual 

moisture determination. (This checl: should be performed after 

the first run.) 

Heasure or have the test firm remeasure the nozzle diameter to 

verify it's calibration. (This should be performed for each 

nozzle utilized.) 

? 
Control Equipment - Compliance Demonstration Checklist 

Electrostatic Frecioitators (ESP) : 

Type (i.e., hot-side, cold-side, =_tc.): 

Number of chambers (sections) : 

Number of fi el dsi chamber: 

h'umber and identification of the fields out of service during the 

test peri od: 

Inaicate the secondary voltage and current ror each operating 

field: 

Indicate the spark rate from each operatina field: 

Indicate the ESP's rapping sequence: 

Indicate the temperature necessary to bring the ESP on line: 

Additional information or comments: 

Fabric Filter (baohouse) : 

Type o•r' filtration (pulse jet, reverse •afr, shakers, etc.): 

Number of compartments: 

Number of bagslcompartment: 

Indicate pressure drop: ' 

Indicate operating temperatur.e: 

Indicate the flow rate to the system: 

Indicate the bag cleaning sequence: 

Additional information or comments: 

f 

r (o~ 
METROPOLITAN INDUSTRIES INC o 

Application No. 15-883 ~-~~, C~ 17Z 

Page 4 of 8 ~ 

June 16, 1993 , 

Ohio Permit Allowable 

EPA Source Applicable Mass Emissions and/ 

Source Identification/ BAT Federal and or Control & Usage 

Number Description Determination OAC Rules Rectuirements 

P006 Natural Gas Fired Limit of 3745-31-05 3 lbs PM/hr 

Tile Tunnel Kiln; Sulfur Content 3745-17-07 13.14 tons PM/yr 

Kiln 7#3 in Raw Mater- 3745-18-06 ~~25_1 s SO 

ials; Limit Of (D)(1) *231.13 tons S02yr 

Amount of Raw 3745-17-11 5 lbs NO /hr 

Materials Used 21.9 tons NO /yr 

In a Day; 2.2 lbs FluoLdes/ 

Natural Gas hr; 9.64 tons 

Usage; 45 meter Fluorides/ r 

High Stack For 

Sources P004, 7 ~ ,~f fu1 /~r, P005 and P006 ~ 

* The combined S0 2 emissions from P004, P005 and P006. ~fe' 

SUMMARY 

TOTAL PERMIT TO INSTALL ALLOWABLE EMISSIONS 

Pollutant 

S02 

PM 

NO 

Fluorides 

Tons/Year 

231.13 ** 

13.14 

21.9 

9.64 

** Combined emissions from P004; P005 and P006. 

PERFORMANCE TEST REOUIREMENTS 

The permittee shall conduct, or have conducted, performance 

testing on the air contaminant source(s) in accordance with 

procedures approved by the Agency. Two copies of the written 

report shall be submitted and signed by the person responsible 

for the test, describing the test procedures followed and the 

results of such tests. The Director, or an Ohio EPA 

representative, shall be allowed to witness the tests, examine 

testing equipment, and require the acquisition or submission of 

data and information necessary to assure that the source 

operation and testing procedures provide a valid characterization 

of the emissions from the source and/or the performance of the 

control equipment. 

a 
METROPOLITAN INDUSTRIES INC 

Application No. 15-883 

Page 7 of 8 

June 16, 1993 

ADDITIONAL SPECIAL TERMS AND CONDITIONS 

1. The sulfur content of the raw materials (clay and shale) 

used in kilns [#1 (P004), #2 (P005) and #3 (P006)J shall 

not exceed .157 % on a monthly weighted average. This limit 

may be adjusted based on the stack test results after 

startup. A weekly analysis of sulfur content taken from 

daily clay and shale samples should be determined. _ 

At any one time, only two the three kilns can be using a 

100% clay mix with no shale. The third kiln must be using 

a mix with a shale content of at least 40$. 

No more than 79 tons of raw materials shall be used in each 

kiln in any one day. 

The facility shall--m—dl-fff ain monthly records which: 

1. list the average sulfur content (percent) of daily clay 

and shale composite samples; 

2. list the clay and sulfur content of mixes used in each 

kiln each day; and 

3. list the daily tonnage of the clay and shale used in 

each kiln. 

These monthly records shall be retained in the facility 

files for at least two (2) years and shall be made 

available for .inspection upon request of the Director or 

any authorized representative of the Director during normal 

business hours. 

This facility shall submit quarterly reports to the Canton 

City Health Department, Air Pollution Control Division, 420 

Market Ave North, Canton, Ohio 44702, which summarize , : 

1. the monthly weighted average sulfur content of the raw 

materials (clay and shale) used; 

2. the daily clay and shale content of raw material used; 

and 

3. the daily tonnage of the,raw materials (clay and shale) 

used in each of the three kilns. 

These quarterly reports shall be submitted by February 15, 

May 15, August 15 and November 15 of each year and shall 

cover the -Dxe.vious ~endar uarter. 

2. The stack servicing kiln (P006) will be a minimum of 

meters high above the ground. 
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COi'lir=;OL =QlJI,ri"EfiT- /~ N~-~------------------------------------------------ 

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17ii I E LS1 +1 F 1..S 1 ~V_~ f~ !~ /I ~3_________________________________ 

F?N;,L 7=Si REPG=.i F:ECEI`.'EJ GN -D ~ C-- Z' ~-'~ ~=3----------------------- 

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