... . •-. "-: : . Poilution.-Control SystemEvaluations.. arid.Boiler Performance .Testing 

- . F•hone. (205) .491.6676 Fax (205)-491-6614 -.- 
Entec Services, Inc. 

16 D Commerce Avenue 

Hueytown, Alabama 35023 

Telephone: 

Fax: 

(205) 491-6676 

(205) 491-6614 

Results of the February 3, 2004 

Compliance Emissions Testing for the 

Tunnel Kiln -located at the 

Fairmount Facility 

located in Fairmount, Georgia 

Georgia Department of Natural Resources 

Permit No. 3251-064-0073.S-01-0 

Submitted to: 

Pine Hall Brick Company, inc. 

P.O. Box 836 

Madison, North Carolina 27025 

Entec Project No. 23159 

Completed By:- .. 

Attention: Mr. Harold Newman 

Report Submitted: Februar• 25, 2004 

R•viewed. By: 

Tommy Lotz, Jr. 

Project Manager 

Glen Corley 

General Manager 
REPORT CERTIFICATION 

The sampling and analysis performed for this report were carded out under my direction and 

hereby certify that the test report is authentic and accurate to the best of my knowledge. 

Date: Signature: 

l.alan Kirby 

Project Manager 

have reviewed the testing details and results of this report, and hereby certify that the test 

report is authentic and accurate to the best of my knowledge. 

Glen Codey 

General Manager 

SOURCE OWNER: Pine Hall Brick Company 

OPERATOR'S LOC•ATION: 

SE)UR/CE(S),NAME(S): 

.SOUR(•E•S) C•)NDITION: 

SOURCE(S) SHAPE: 

Falrmount, Georgia 

Tunnel Kiln Outlet 

Compliance 

Olmuiar 

PROBE WASH CHEMICAL: Acetone 

SOURCE PERMIT NUMBER: 3251-064-0073-S-01.0 

TESTS PERFORMED: Emissions Testing 

REFERENCE METHOD TESTS: Sample Location 

Volumetrio Flow 

Moie•ular Weight 

Moisture Content 

Suffur Dioxide 

Carbon Dioxide 

Particulate 

Hydrochlodo Acid 

Hydmfloudc A•d 

EPA Method 

EPA Method 2 

EPA Method 3A 

EPA Method 4 

EPA Method 6C 

EPA Method 10 

EPA Method 26A 

.•PA Method 26A 

EPA Method 26A 

TEST SUPERVISOR: l.alan Kirby 

OWNER'S REPRESENTATIVE: Harold Newman 

RULING AGENCY REPRESENTATIVE: DeAnna Oser 

DATES TESTS CONDUCTED: 02/03/04 

ENTEC PROJECT NUMBER: 23159 
Pine Hall Brick Company, inc. 

Table of Contents 

Section Page # 

Executive Summary 

Detailed Test ResultsControl Room Production Data 

Sampling ProcedureS 

/• isokinetic Field Data Sheets 

Test Run 1 

Test Run 2 

Test Run 3 

Instrumental Field Data Sheets 

Test Run t 

Test Run 2 

Test Run 3 

Location of Test Ports 

_Cyclonic Flow Test 

-_Quality Control I Quality Assurance Procedures 

Laboratory Analysis 

Equipment Calibration 

Instrumentation Calibrations 

Test Calculations and Nomenclature 

t 

4 

7 

9 

17 

18 

22 

6 

30 

31 

35 

39 

47 

50 

63 

77 

94 

99 
Executive Summary 

Entec Services, Inc. was retained by Pine Hall Brick Company, inc. to perform 

emissions testing, on the Tunnel Kiln at the Fairmount facility located in Fairmount, 

Georgia. Mr. Tommy Lotz, Jr., Mr. Lalan Kirby, Mr. Joseph Lotz, and Mr. Tom Lotz, Sr. 

conducted the testing on February 3, 2004. Representing Pine Hall Brick Company 

was Mr. Harold Newman who coordinated testing with the control room production 

activity. Ms. DeAnna G. Oser representing Georgia Department of Natural Resources 

observed the testing. 

Emissions were perf.ormed in accordance with EPA CFR .40 Part 60 Appendix "A" 

methods 1, 2, 3A, .4,,. 6C, 10, and 26A. Three, sixty (60) minutes test runs were 

performed o/n th,e source with the Kiln operations at approximately 85 percent load. 

Prior • the first test run a preliminary velocity measurement of the exhaust gas was 

dete•.rrn•'ned to verify the absence of cyclonic flow in the gas stream and to allow the 

selection of the appropriate nozzle diameter for isokinetic sample withdrawal. A Nutech 

Model 2010 sampling train which meets the specifications in the above-cited reference 

methods, was used to isokinetically extract the particulate, hydrogen chloride (HCI), and 

hydrogen fluoride (HF) samples by means of a heated glass lined steel probe and 

heated filter compartment. 

Testing was conducted from two test ports oriented at 90 degree on the exhaust stack. 

The test ports were located 10.85-duct diameters downstream and 2.89 duct diarneters 

upstream from the nearest disturbance. A 12-point traverse was used to determine the 

exhaust gas volumetric flow and to coilecta representative sample of the particulate, 

HCI,oand.HF emissions. Each traverse point was sampled for.five (5) minutes for a total 

sampling time of Sixty (60) minutes for each test run. 

No difficulties were encountered in the field collection of the samples or in the 

laboratory analysis of the samples by Entec Services, Inc. Testing was conducted in 

accordance with the applicable CFR 40 Part 60 Appendix "A" test procedures. 
On the basis of these facts and a complete review of the data and results, it is our 

-opinion that the results reported herein are accurate and closely reflect the actual 

values, which existed at the time the testing was conducted. 

The particulate emissions test summary on the following page gives a detailed 

sumrnar•- •f each tes• Fun compared to the-maximum emission limits set forth by the 

Georgia Department of Natural Resources. Tests. results indicate the emissions 

comply with the Georgia Department of Natural Resources Permit No..3251-064- 

-0073-S-01-0 

Test Its 
ENTEC Services, inc. 

16-D Commerce Ave. Hueytown, Alabama 35023 

EMISSIONS CALCULATIONS 

Client: Pine Hall Brick Company Job No.: 23159 

Source: Tunnel Kiln Outlet 

INPUT DATA 

Data Input By: Tommy Lotz, Jr. 

Run Number 

Test Date 

Time Began-Ended 

Sampling Time, Minutes 

/ 

Stack Area, Square Feet 

Barometric, Pressure, Inches of mercury 

Stack static Pressure, Inches of water 

Pitot Tube Correction factor 

Meter Correction Factor 

Meter Delta H • 

Nozzle Diameter, Inches 

Meter Volume, Cubic feet 

Me•er Temperature, Degrees F 

Avg: Orifice Delta H,.Inche•-of Water 

Highest Vaccum Achieved During Run, in. H 9 

Volume H20 Collected, ml 

.C.O2 Concentration, Percent 

02 Concentration, Percent 

Avg. Sq. Rt of Delta P, Inches of Water 

Stack Temperature, Degrees F 

,Total Hydrogen Chloride collected, mg 

Total Hydrogen Fluodde coll.ected, m 9 

Total particulate collected, mg 

02/03/04 

1000-1121 

60 

12.048 

29,36 

-0,19 

0.993 

1.531 

0.322 

02103104 

1205-1310 

6O 

12.048 

29,36 

0.993 

1.531 

42.504 43,243 

81.3 86.1 

1.31 

.2.5 

92.9 

3.3 

15.5 

0.474 

1.36 

4,0 

90,6 

3 

02/03/O4 

1380-1455 

80 

12.048 

29,36 

-0.20 

0.84 

0.993 

1.531 

0.322 

44,784 

85.5 

1.48 

2.3 

88.1 

3.2 3.4 

15.5 17.1 

0.483 0.504 

393.0 393.5 

5.56 5.16 

1,95 2,02 

392.7 

2.03 

35.7 

AVERAGE 

29.36 

-0,20 

43.5t0 

84.3 

1.38 

90.5 

3.3 

16.0 

0.487 

393.1 

5.35 

2.00 

27.7 22.8 24,5 

-# 
ENTEC Services, inc. 

16-D Commerce Ave. Hueytown, Alabama 35023 

EMISSIONS CALCULATIONS 

Client: Pine Hall Brick Company Job No.: 23159 

Source: Tunnel Kiln Outlet Data Input By: T, Lotz, Jr, 

CALCULATED DATA 

Run Number 2 3 AvERAGE 

Test Date 

Time Began-Ended 

1. Stack Pressure, Inches of mercury 

2. Meter Pres•sure,•l•ches of meroury 

3. Standard Meter v•Ium•, Cubic Feet 

Standard Water Volume, Cubic. Feet 

5. Moisture Fraction 

9. Molecular Weight Of Stack Gas, dry basis 

!10. Molecular Weight Of Stack Gas, wet basis 

! 1. Average Stack Gas Velocity, Feet/Second 

12. Stack Gas Flow (• Stack Conditions, ACFM 

13. Stack Gas Flow @ Standard Conditions, DSCFM 

14a. Particulate concentration @ Std.Cond.,Grains/Cu.Ft. 

14b. Hydrogen Chiodde concentration (• Std.Cond.,Grains/Cu.Ft. 

14c. Hydrogen Fluoride concentration @ Std.Cond.,GrainslCu.Ft. 

15a. Particulate*emissions, Ibs per hour -'. 

15b. Hydrogen Chlodde emissions, Ibs per hour 

15c. Hydrogen Fluoride emissions, Ibs per hour 

16. Volume collected through nozzle, ACF 

17. Isokinetic Sampling Rate, Percent 

!Post Mater Orifice Cal. (EMC ALT-009 Yqa) 

!% Difference, (must be within 5% of odgional Y-factor) 

0•0•04 

1000-1121 

29.35 

29.46 

40.513 

4.373 

0.097 

29.142 

28.057 

34.625 

25,030 

13,710 

02103104 02/03/04 

1205-1310 1350-1455 

29.35 29.35 

29.46 

40.863 

4.265 

0.094 

29.128 

28.077 

35.273 

25,498 

14,003 

0.0093 

29.47 

0.25 0.23 0.24 0.24 

0.09 0.09 0.09 0.09 

73.963 74.408 76.637 75.003 

104.93 103.62 102.42 103.66 

0.9972 1.0026 1.0098 1.0032 

-1.03% 

1.02 

0.0021 0.0020 0.0020 

0.0007 0.0008 0.0008 0.0008 

36.754 

26,569 

14,692 

-0.0136 

0.0020 

1.71 

42.378 

4.147 •261 

0.089 0.094 

29.223 29.165 

28.222 28.119 

29.46 

41.251 

35.551 

25,699 

14,135 

0.0105 

1.28 

0.0087. 

29.35 
Co.•u•trol Room Production Data 
Control Room Data 

The feed rate in terms of tons of brick per hour was taken by Mr. Harold Newman of 

Pine Hall Brick Company, inc. and was averaged for the testing performed on February 

3, 2004. The results are located on the emissions summary page, Mr. Harold Newman 

took readings for the lime bed dry scrubber control device. The readings were for 

pressure drop across the lime bed in units bf mill bars (mm) and for lime discharge 

(lbs/hr). The data is located on th$ following page. 
Sampling 
Procedures 

The emission rates were determined using EPA Methods 1, 2, 3A, 4, 6C, 10, and 26A, 

CFR Title 40, Part 60, Appendix A. The calibration and quality assurance procedures of 

EPA CFR 40 Part 60 Appendix A for all methods, and the "Quality Assurance 

Handbook for Air Pollution Measurement System" Volume II! Stationary Source-Specific 

Methods were followed throughout the duration of the field and laboratory testing. 

The most current revision revised as of. July 1, 2001, of each method (as described in 

the Federal Register) was used. 

Stack Gas Volumetri, c Flow 

The veio•city-,of the gas stream was determined according to EPA Reference Method I 

/ 

and 2"by reading the instantaneous velocity head with an inclined manometer at each 

sam•iirrgl•oint with a calibrated S-type pitot tube attached adjacent to the sample 

nozzle. The stack pressure was measured with the static side of an S-type pitot tube. 

.•, calibrated pyrometer was used to measure stack temperature at each sampling point. 

The stack was tested for cyclonic flow according to EPA Reference Method 1. 

Stack Gas-Molecular Weight 

The carbon dioxide concentrations were determined using EPA Reference Method 3A. 

The molecular weight of the gas was calculated using the moisture, oxygen and carbon 

dioxide content and the measured stack gas temperature. 

Moisture Co•tent 

The moisture content used for ,calculating the gas stream flow rate was determined-by 

weighing the amount of condensed moisturecollected in the "•mpingers of the sampling 

train as described in EPA Reference Method 4. 
Particulate, Hydrogen Chloride, and Hydrogen Fluoride 

Preliminary data was used to determine stack temperature, pressure, and range of 

velocity heads, moisture content and stack gas dry molecular weight prior to sampling. 

The meter box was leak checked from the pump to the orifice. Initial and final leak 

checks of the sampling system and pitot lines were performed as outlined in Method 5 

and were recorded on the data sheets. The nozzle (glass with an angle of taper of 30 

degrees and of button hook design) .was calibrated before_ •nrl =f•r •h= •,•÷ ,,o•,,•., 

micrometer.and was also recorded on the data sheets. 

The sampling probe was placed at each sampling point to provide a total sampling time 

of 60 minutes. The gases were drawn through a glass nozzle attached to a heated 

glass lined probe. Tfie probe was maintained at the proper setting to obtain an exit 

temperature pf 248 _+ 25 0 F, The gases then proceeded through borosilicate glass filter 

holder, with a" Teflon frit filter support through a glass fiber filter to remove particulate ; 

matter. The filter wasmaintained at a temperature of 248 + 25 0 F. These temperatures were recorded at each point on the data sheets. 

The gases were then scrubbed through a series of four impingers to capture hydrogen 

halides• and halogens and moisture. (The optional first impinger for a knockout for 

moisture was not used.) The first and second impingers contained approximately 100 

ml of a 0.1N H2SO4 solution and the third and fourth, impinger contained approximately 

100 ml of a 0.1 N NaOH solution. The fifth impinger contained pre weighed silica gel to 

..remove any remaining moisture.. The gases pass through the impinger series in an ice 

bath to maintain a maximum •:exit temperature of 68 0 F. This temperature was also 

recorded on the data sheets. The clear• and cool-gases then entered the meter box 

where ths gas flow and temperature were measured. 

After the completion of the test the sampling train and the probe nozzle assembly was 

transferred to the cleanup area making sure no particulate was lost. The cleanup data 

was recorded. 
Particulate catches were placed in sealed petri dishes. Each acetone rinse from the 

nozzle, probe, and filter holder was combined and placed in a sealed container. For the 

group of tests an acetone blank of approximately 200 milliliters was placed in a sealed 

container. The first and second impinger contents were transferred to its tared 

container, weighed and the rinsing from the glassware were added to this container. 

The third and fourth impinger was transferred to its respective tared container, weighed 

and the rinsing from the glassware was added to this container. The. silica ge! from the 

fifth impinger was transferred to its respective tared container and weighed. A blank of 

the sulfuric acid solution, sodium hydroxide, distilled water and acetone was taken. All 

containers were clearly marked, logged in, and shipped, to a State of Georgia approved 

certified laboratory, for analysis. 

Oxy_qen- ./ 

Ti•e 0•'ygen..content in the flue gas was determined using a Siemens Ultramat 23 

ox'y•ed analyzer. The Ultramat 23 uses an electrochemical cell that consumes oxygen 

from the atmosphere surrounding the cell. The consumption of the oxygen, generates a 

proportional electrical current. This current is then amplified and provides- a signal 

output of 4-20ma signals, which corresponds to a full-scale range of 0-25% oxygen. 

Carbon Dioxide 

Carbon dioxide concentrations were continuously measured with a Siemens Ultramat 

23 non-dispersive infrared (NDIR)analyzer. The theory of operation for this analyzer is 

based on the principle that CO2 has a unique absorption line spectrum in the infrared 

region. The instrument consist• of an irtfrared light.source, a chopper, a measurement 

cell, and a d•tector. The infrared light beam emitted by the source .passes through the 

mea•sur!,ng cell, which is filled .with a continuously flowing .gas..sample. The light beam is 

partially absorbed or attenuated by the gas species ot interest in this cell before 

reaching the front chamber of the detector. Both the front and rear chambers of the 

sealed detector are filled with a reference gas. The difference in the amount of light 

absorbed between the front and rear chambers are dependent on the concentration of 

the gas species of interest within the sample measurement cell; a pressure differential 
is thus created between the two chambers. This pressure difference is then observed 

as gas flow by the micro-flow sensor located in a channel connecting the two chambers. 

The resulting AC signal from the micro-flow sensor is rectified, amplified and iinearized 

into a 4-20ma signal for output that corresponds to a full-scale 0-25% measurement 

range. 

Sulfur Dioxide 

A Western Research Model 721M SO2 analyzer provided continuous analysis of SO2 in 

the gas stream. The basic analytical principle involves quantitative measurement of the 

absorption of UV radiation by •SO2 molecules. The analyzer uses a single light source, 

which emits an appropriate wavelength, illuminating the sample cell throughwhich the 

sample is continuously passed. Narrow-band optical filters are rotated through the 

beam, and tr)e ra, diation passed through the optical filters and sample cell !s detected 

by a single photo,detector. The signal pulses from the photo-detector are separatedby 

a multiplexor into a measuring channel and-a reference Channel. A log ratio ampiifier. 

computes the logarithm of the input signal ration, producing a signal that is' proportional 

to the SO2 concentration. The duat-range analyzer has a digital readout, as well as 0- 

10.0 V DC output •erminals. The full scale of the instrument was setat 100 ppm 

Carbon Monoxide 

The CO •vas measured using a Siemens Ultramat 23 .analyzer. T-his monitor is a 

selective non-dispersive infrared radiation (NDIR) gas analyzer that operates-, on the 

infrared doubi•beam alternating, light .principle. The full-range for the CO component of 

this instrument throughout the test period Was t000 ppm. 

Sampling System :. '.... 

Samples were extracted from the gas stream by a heated stainless steel-probe• 

maintained at a set temperature of 250 degrees Fahrenheit, through a ten (10) foot 

heated sample line that was heated to a temperature between 225 and 250 degrees, 

through a chilled sample conditioner to remove the moisture in the.gas stream and 

transported to the test trailer through unheated teflon sample lines to the analyzers. 
Da• Aca.uisition 

Concentrations were collected at each fifteen-second, interval and averaged at each 

-ten-second and sixty-second intervals with a Parametrics data acquisition system. 

During all testing, the unit was operating within normal operating parameters; at a range 

appropriate in accordance with applicable permits.