AP-42 Section ~ j•7— Reference }

~ 

### 9 3Report 

# Envisage Environmental Incorporated REPORT NO. Reference ~ P.O. Box 152, Richfield, Ohio 44286 COMPANY MPt



# ___ Phone (216) 526-0990 TITLE 

# Comy

~ 

# ___ 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 Environmental


### - Incorporated 

# _ P.O. Box 152 Rlohfieltl. Ohio 44266 Phone (216) 526-09902



# 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

Environmental


## - Incorporated

- P.O. 90x 152 Richlleld, Ohio 44266 Phone (216) 526-09904



# DESCRIPTION OF PROGRAM

~ Envisage

Envlronmental - Inoorporated

- 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

_ Envlsage Envlronmental


## - Incorporated

- 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

Environmental


## - Inoorporated

- 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



### ~ Envisage

Environmental - Incorporated 

# _ 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

Environmental - Incorporated

- P.O. Box 152 tiICh11e10. OhiO 44286 Phone (216) 526-0990Symbol

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 

# _ 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 e Wa r

lQ m ------------- 

## Point # ------- 

## D 

## insaRe e WayQ m

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



# _ Envisage Environmental - Incorporated

- P.O. Box 152 FIehllBltl, OhiO 44266 Phone (216) 526-0990 

### IA

# LABORATORY SECTION 12



## ~ Envlsage

Environmental 

## ~ Incorporated

- P.O. Box 152 Rithlield. OhiO 44286

Phone (216) 526-0990LABORATORY 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) 526-0990LABORATORY 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



## ~ Envlsage

Environmental - Inoorporated 

# _ P.O. Box 152 Rlohlieltl, Ohio 44266 Phone (216) 526-099012/15%93 13:51 MSL ANALYTI[,HL 001 

# ' cAL ` ANALYTI 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 f 3 250 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 Mana9erL}1clJnr+ I vn T I

COMPANY 

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## SIUCA GB? FiNAL INITtAL 

## NE7 1o. 

# ~ a. - Z 

# ~ 1,•z, 

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# ~ PARTiCULATE 

## PROBE FiNAL ~~.~1 l~1 1~ 

## . 212 ~ 

## ' -J I ~J• ~3~~ 

## INRIAL NL f I I FLTEq 

## 1N N ITL4 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

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### 4-n Envisage Environmentaf - Incarporated 

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

ar+m. aim 5254M .lf



### ~ QE:,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

_ Envlsage

Environmental - Incorporated

- P.O. Boz 152 Richfleltl. Ohio 44286

Phone (216) 526-0990 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) 526-099021

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# CALIBRATION SECTION K-~



## ~ Envlsage

Envlronmental - Incorporated

- 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

g 

### lass 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

# GRASEBY a 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 V w ft 3 Dry gas

meter volume V m ft 3 Tem eratures Time 0 min Spirometer (wet meter) t w
° F Dr 

### v Gas Meter

Inlet t i

° F Outlet t o

° 

### F Average t m

° 

### F 1.0 5 

### y, l93 2.0 5 

### ; i B'- 1 7' /z/ 

### 7S, 7 0 

# ~ ''Z. v~ 

### ..s G, 3--3 4.0 

### S .S' /yS 7G, f l zs 5r5i 0 1 1,.s .SC7 Calculations



## AH in. H20 

## Y AH@

yw Pb (t m + 

### 460) 2 0.0317 0 H (t w

+ 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. 1 1C or duct, fr.'

- . A a = 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. C S = Concentrat:en of particulate matter in aas stream, dry basis-corrected to 

### v standard conditions, gr/dsc: D a = 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;, %. K p = Pitot tube constant, 85.T9 ft./sec. lY1 a = Molecular weiah t of gas, drv basis, lb./lb.-mole. Total amount of partiealate matter collected, g. Ni s = Molecular weia-ht of oas, wet basis, Ib./Ib: mole. N,„ = Molecular weight of water, 18 Ib./lb.-mole. pbar = Baromet ri 

### c press•sre, in. of H v . p g = Pressure diiferential from aas stream to atmosphere,

(static pressure) in. of H 2 O. p s = Absolute gas stream pressure,(P b ~ 

### + P e /13.6) in. of H. pstd = Absolute pressure at standard conditions, 29.92 in. of H. p w . = 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. T m = Average dry gas meter temperature, ° R. T S = Average absolute aas stream temperar.:re, ° R. Tstd = Standard absolute temperature, 528 ° ranldne. V tC = Volume of water collected in i.mpingers and silica oel, mI. V m = 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
. 

### V s = 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). %' o 0 : = Percent by volume of 0, in gas stream (dry basis). %aC0 = Percent by volume of CO in g as stream (dry basis). 

## q a N : = Percent by volume of N 2 in gas stream (dry basis).



## ~ Envisage Envlronmental - Incorporated 

# _ P.O. 8ox 152 RlOhfleltl. OhiO 44286 Phone (216) 526-098036



# EMISSION SAMPLING CALCULATIONS

- Envisage Environmental

- Incorporated

- P.O. Box 152 fiiChllBltl. OhiO 44286 Phone (216) 526-09901) Volume

- of

- dry

- gas - sampled

- through

- meter
- box

- at
- standard

- conditions, 

### _^H_ V = V

_ T _std P b +

--- 

### --_13.6

___ m(std) m 

## T m Pstd (EPA Equation 5-1) Where: Vm(std)- Volume of gas sample mea5ured at meter box (corrected to

standard conditions), ft . V m = Volume of gas simple measured at meter box (meter



### condi

- tions), ft . T st d = Standard absolute temperature, 528 0 Rankine. T m = Average dry gas meter temperature, o R. P bar = 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 ft 3 m T = 532.1 

## o R m ^H = 1.55 in. H 2 0 P bar = 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 ft 3 _ 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)= V lc

-- 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
. V lc = Volume of water collected in impingers & silica gel, ml. 

### P w = Density of water, 0.0022 lb/ml. M = Molecular weight of water, 18 lb/lb-mole. 

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

## T std = Standard absolute temperature, 528 ° Rankine. 

## P std = 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 ft 3



## ~ Envlsage Environmental - Incorporated

- P.O. Box 152 Rlchiield. Ohio 44286 Phone (216) 526-0990 

# 740

4) Dry

- Molecular

- Weight

- of

- gas

- in

- gas

- stream, ----------------------------------

M d = 0.440 (%CO 2 ) + 0.320 (%A 2 ) + 0.280 (%N 2 + %CO) (EPA Equation 3-2) Where: M d = Molecular weight of gas, dry basis, lb/lb-mole. 0.440 = Molecular weight of CO 2 divided by 100. 0.320 = Molecular weight of 0 2 divided by 100. 0.280 = Molecular weight of N 2 or CO (same for both compounds)

divided by 100. % CO 2 = Percent by volume of CO 2 in gas stream (dry basis). % 0 2 = Percent by volume of 0 2 in gas stream (dry basis). % CO = Percent by volume of CO in gas stream (dry basis). % N 2 = Percent by volume of N 2 in gas stream (dry basis). Example: Run 1
% CO 2 = 8.4 % 0 2 = 16.5 % CO = 0.0 9'o N 2 = 75.1
M d = 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

### 42

6) Average

- Gas

- Stream

- Velocity, 

### ------------------------
V= s T



### K C ^P - - s -- P P av9 P s M s \ (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, o R. Absolute gas stream pressure,(Pbar + P g /13.6) in.Hg. Barometric Pressure, in. Hg. Pressure differential from gas stream to atmosphere, (static pressure) in.H 2 O. Molecular weight of gas, wet basis, lb/lb-mole. Where: 

### V s = K p = 

## C = P AP avg 

### T s = P s P bar 

### P g = M s = Example: Run 1 

## C = P AP avg 

## T = s Ps M s = 0.84

0.134 in.H 2 O 1/2 721.5 o R Pbar + P g /13.6 = 28.78 + 29.26 lb/lb-mole -0.02 /13.6 = 28.78 in.Hg

------------------------- V s = ( 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) 526-099044

8)' Volumetric

- Flow

- Rate

- at

- Standard

- Conditions, -------------------------------------- Q = 60 ( 1- B ) V A
_ T std

- - - -- 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. B ws = Water vapor in gas stream, proportion by volume. V s = Average gas stream velocity, ft/sec. A = Cross sectional area of stack or duct, ft 2
. 

## T std = Standard absolute temperature, 528 ° Rankine. T s = Average absolute gas stream temperature, ° R. P s = Absolute gas stream pressure,(Pbar + P g /13.6) in.Hg. 

## P bar = Barometric Pressure, in. Hg. P g = 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 V s = 8.91 ft/sec A = 19.63 ft 2 T = 721.5 ° R s 

## P s Pbar + P g /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 = 15.43 gr./g

- ~ 

### --n---- s 

### m(std) (EPA Equation 5-6)
Where: C s = Concentration of particulate matter in gas stream, dry

basis-corrected to standard conditions, gr/dscf. M n = 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

M n = 0.0425 g Vm(std) 43.18 ft 3

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)526-099010) 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. R sd = 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 ft 3

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 

# 711) Percent
- of

- Isokinetic Sampling, 47 

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

## I 3 lc T m bar
_ s 13.6

----------- ---------- 60
--- A ---- ~ 

### ---- P ----t-------(EPA Where: n s s Equation 5-7 I = Percent of Isokinetic sampling, %. T s = Average absolute gas stream temperature, ° R. 

### K 3 = Constant, 0.002669 in.Hg-ft 3 /ml- ° R. V lc = Volume of water collected in impingers & silica gel, ml. V m = Gas sample volume measured at meter box (meter conditions), ft 3
. T m = Average dry gas meter temperature, ° R. 

# P bar = Barometric Pressure, in. Hg. ^H = Average pressure differential across orifice, in. H 2 0. 

### t = Total sampling time, minutes. V s = Average gas stream velocity, ft/sec'. P s = Absolute gas stream pressure, in.Hg. 

### D n = Nominal diameter of probe nozzle tip, inches. A n = Cross sectional area of nozzle, ft 2
. 

### Example: Run 1 T s = 721.5 

# ° R ^H = 1.55 in.H 2 O V lc = 60.6 ml t = 60.0 min. ft 3 V m = 45.06 V s = 8.91 ft/sec T m = 532.1 

# ° R P s = 28.78 in.Hg ft2 A n = 0.0020294 

# P bar = 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 - ------ 10 6

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 68 0 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 = L O.84953i 

### nox -------------------------- --------------------- 10 6 =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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### ~ c. ML1



### 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 SO 2 , 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 SO Z testing. 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 S0 2 /yr should read *52.77 lbs S0 2 /hr or 19.26 lbs SO Z /hr. The * was to denote combined emissions from P004, P005 and P006. My observations on the 17 1consisted of watching only one run on the gas sampling end of the test. VOC, NO x , SO Z 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 x recordings 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 2 CEM 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 SO Z CEM 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 Z sample 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 S0 2 = 22 827 815 447.7 ? NO x = 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" (H Z O). 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



# 2EPACST.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

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### Ki . in/day.1 /kiin/daya s5 i 2,2 , 77 ;6 fi ; 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 ! .., ...... ,... . =_ L ; ATES ~ 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 ? 1 70.233 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/Brk i 0.223 { 0.14 ; 0.363 1 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 `5/24.75 7 /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 j S of cfays 1 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. ~ 40-7.13.91 2.2 ' 7/19...7/25 !; 57X.105 ' New Nort 0.288 j 0.314 ! 0.602 F 40 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 MIX i 0.181 ! 0.058 j 0.239 ; 40 ; 2.2 To date Averagel 0.1293 j M/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

88ENAC: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
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### i 0

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~ 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~

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# ` :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

/

~ vDate:

Observ. Faci i i ty Source: Test Fir, . • • . ~ ~ ~`~ iC;-. G ~ c~e~ , er-

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## ~ 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 ~ ✓

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✓ ~~ ~ - 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; ) A) oX~ o ^~ C
C<! /// -A--1 ~ re '.ri.. 1-4 ej ~ - - . i Z,.. ~ - ~ - ~ 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 S0 2 yr 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 fu 1 /~ r

, 

### P005 and P006 

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

# ~ fe '

SUMMARY TOTAL PERMIT TO INSTALL ALLOWABLE EMISSIONS Pollutant S0 2 

### 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.N —z

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