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FLUORIDE CASCADE ABSORBER EbIISSION EVALUATION CAROLINA CERAbIICS COLUMBIA, SOUTFI CAROLINAi FLUORIDE CASCADE ABSORBER EMISSION EVALUATION CAAOLINA CERAMICS COLUMBIA, SOUTH CAROLINA



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r JANUARY, 2001 DAVIS & FLOYD, INC. JOB NUMBER 61381.00



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~ PREPARED BY


## ~ DAVIS & FLOYD, INC. ENVIRONMENTAL DIVISION GREENWOOD, SOUTH CAROLINA
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Enrironmental & La6oratary Serrices
P.O. Drawer 428 Greenwood, SC 29648 • 816 East Durst Avenue Greenwood, SC 29649 •(864) 229-4413 (office) (864) 229-7119 (fax) January 19, 2001 Serial No. HGA-006-01 Job No.: 61381.00

Mr. Ken Newell Carolina Ceramics 9931 Two-Notch Road Columbia, SC 29223-4390 Reference: Emission Testing on Fluoride Cascade Absorber Dear Mr. Newell: Davis & Eloyd, Inc. conducted source test sampling at Carolina Ceramics, Columbia, South Carolina, on December 12, 2000. These tests were conducted on the outlet gases of the fluoride cascade absorber. Two copies of the report containing the results of this project are enclosed. A copy of this report has been mailed to Mr. Jason Hobbs, South Carolina Department of Health and Environmental Control, Bureau of Air Quality, 2600 Bull Street, Columbia, SC, 29201. We would like to express our appreciation to you and the Carolina Ceramics personnel involved in this project for their assistance in the areas of scheduling, physical arrangements, etc. Should you have any questions regarding this work or report, or if we may be of additional assistance, please do not hesitate to contact us. Sincerely, DAVIS & FLOYD, INC.
H. Gary Anderson, Jr. Field Services Environmental Division Enclosures: As stated in letterTABLE OF CONTENTS PAGE 1.1 2.1 3.1 4.1 4.1 4.1 4.1 4.2 5.1 1.0 INTRODUCTION 2.0 TEST OBJECTIVES 3.0 PROCESS DESCRIPTION 4.0 SAMPLING AND ANALYTICAL PROCEDURES 4.1 Velocity Traverse Point Locations 4.2 Volumetric Flow Rate 4.3 Moisture and Molecular Weight 4.4 Hydrogen Fluoride and Hydrogen Chloride and Chlorine Concentrations 5.0 SAMPLING RESDLTS Table 5.1 Hydrogen Fluoride Emission Results Table 5.2 Hydrogen Chloride Results Table 5.3 Chlorine Emission Results Table 5.4 Particulate Emission Results
APPENDICES APPENDIX 1 EPA Method 5 and 26A Data Reduction APPENDIX 2 Calculations APPENDIX3 Field Data Field Equipment Calibrations APPENDIX 4 Laboratory Data Production Data

H:WDMINDAT\PLOTHRID\HGA\01\61381-Carolina Ceramics.doc DAVIS & FLOYD, INC.

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1.0 INTRODUCTION Carolina Ceramics, located in Columbia, South Carolina, is a manufacturer of ceramic brick. A part of this process is the drying or curing of the brick, which is done in ovens referred to as kilns. On December 12, 2000, emission tests were conducted for the halides hydrogen fluoride, hydrogen chloride, and the halogen chlorine on the outlet gases of the recently installed fluoride cascade absorber. Stanley Broome and Brandon Wilson of Davis & Floyd, Inc. performed this testing.
These tests were observed by South Carolina Department of Health and Environmental Control (SCDHEC) representative, T. J. Lancaster.

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2.0 TEST OBJECTIVES The objective of this testing was to demonstrate compliance with South Carolina Department of Health ~ and Environmental Control (SCDHEC) established air standards for hydrogen fluoride, hydrogen


# ~ chloride, and chlorine using EPA Method 26A (Determination of Hydrogcn Halide and Halogen


# ~ Emissions from Stationary Sources — Isokinetic Method) and particulate emissions using EPA Method 5.

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3.0 PROCESS DESCRIPTION 3.1 The process is the firing of dried brick products 31.27 hours from entrance of kiln to exiting kiln through an "intermittent push" tunnel kiln. Intermittent push is defined as 

### moving the product a certain distance through the kiln and th0n holding the product stationary for a specific amount of time. The product does not move on a continuous basis. The kiln sections are described as follows: Pre-heat Section, Firing Section, Quick Cool Section, and Slow Cool Section. During the preheating of the product, fluorine,

i~ which is present in the raw material, is released and combines with hydrogen inside the kiln and forms gaseous hydrogen fluoride. This hydrogen fluoride is then exhausted into % a duct and travels through stacked beds of limestone. The Irydrogen fluoride reacts with the limestone to form calcium fluoride. The clean air is then exhausted into the

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## !s 3.2 The designed rate: 207.9 tons/day fired. Test Rate: 208.5 tons/day fired. 

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3.3 The production rate for the kiln, in tons per hour, was recorded for the test as follows: Push Speed x Brick Per Car x Average Weight of Unit = 2000 = Fired Tonnage Rate


## I~ 3.4 This fluorine cascade absorber is manufactured by Hellmich. It is a Model No. 1528.
t The flue gas is conducted via a pipeline to a collecting hood. In the hood, the flue gases 

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### ' are distributed over the flue gas cascades of roof-shape design. From there, the gases flow through uniformly poured crushed limestone granules into the cleaned gas 

## i7 cascades. During this, the crushed limestone absorbs the HF contained in the flue gas.



## ~ From the cleaned gas cascades, the cleaned exhaust air is conducted in a pipeline further 

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## I via a collecting hood to the fan. The crushed used limestone is discharged intermittently

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~ ADMINDA7\PLOTHRID\HGA\01\61381-CarolinaCecamics.doc ; DAVIS & rLOYD, INC. — ~ j~3.2 via a screw conveyor. The crushed limestone stored in a storage silo subsides at the same time. To ensure that the flue and cleaned gas cascades are always fully covered, they must be topped up with crushed limestone within a suitable period of time. The storage silos are filled by means of pneumatic trucks. The delivery air is filtered through the poured limestone and taken to the cleaned gas hood. The FCA is insulated in order to avoid loss of heat through the outer skin of the absorber.

3.5 There are no stack gas or opacity monitoring systems associated with the dry lime sorption scrubber.

3.6 A time control system associated with the discharge of spent lime from the scrubber

e ensures that the limestone continues to fall down evenly from the storage silo over the cascades, thus making sure that adsorption of the hydrogen fluoride and the utilization of the limestone granules are optimal. The control monitors are as follows: Pressure drop across scrubber, Thermocouple, and lime purge cycle.

3.8 During the emission test, the process rate and kiln temperature of the kiln were recorded by Carolina Ceramics personnel. It was the responsibility of the kiln supervisor to collect this information.

H:\ADMINDAT\PLOTHRID\HGA\01\61381-Cuolina Ceramics.doc DAVIS & FLOYD, INC.

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4.0 SAMPLING AND ANALYTICAL PROCEDURES 4.1 Velocity Traverse Point Locations The velocity traverse point locations were selected in accordance with EPA Method l, "Sample and Velocity Traverses for Stationary Sources". The scrubber exhaust is equipped with a circular stack that is 48 inches in diameter. Two sample ports were located on the circumference of the stack at a location that was approximately 42 feet downstream of the nearest flow disturbance 11.5 feet from and upstream the top of the stack. Twelve (12) traverse points were selected for velocity determinations, 6 along each sample port cross-section (see Figure 1).

4.2 Volumetric Flow Rate Stack gas volumetric flow rate was determined in accordance with EPA Method 2, "! ` )etermination of Stack Gas Velocity and Vohimetric Flow Rate". This was performed in

r; conjunction with EPA Method 26A.

4.3 Moisture and Molecular Weieht Stack gas moisture content was determined as per EPA Method 4, "Deterrnination of Moisture Content in Stack Gases" in conjunction with EPA Method 26A. Stack gas molecular weight was determined by obtaining samples and analyzing for oxygen and carbon dioxide concentrations using a Teledyne Max-5 combustion analyzer and was found to be near ambient condition.



# ~ 4.4 Hydroeen Fluoride, Hydroeen Chloride, and Chlorine Concentration 

# ~ Hydrogen Fluoride, Hydrogen Chloride, and Chlorine concentrations were determined in

accordance with EPA Method 26A, "Determfnatfon of Hydrogen Halfde and Halogen Emissfons

5 - from Stationary Sources - Isokinetic Method'. Three one-hour test runs were conducted. The 

# ~ sample train consisted of a one-piece glass-lined probe and glass nozzle, a glass fiber filter

H:\ADMINDA '[1PLOTHRII)\HGA\01 \61381-Carol ina Ceramics.doc I DAVIS & rLOYD, INC. —4.2 (Teflon mat, Pallflex), EPA Method 5 glass impingers, and an EPA Method 5 control console. The first two impingers contained 100 ml each of 0.1 N sulfuric acid, the third and fourth impingers each contained 0.1N sodium hydroxide, and the fifth impinger contained 200 milligrams of silica gel. After the testing was completed, the samples were transported to the laboratory where the volume of the impinger catch was measured, the silica gel was weighed, and the impinger solution was transferred to EPA protocol tvashed glass sample bottles. The impingers were then rinsed with a known volume of D. I. water, and the rinse was combined with the samples. The samples lvere then analyzed using ion ®hromatography as specified in the method.

4.5 Particulate Concentration
e Particulate emission concentrations and emission rates on the outlet ex}laust stack were determined in accordance cvith EPA Method 5, "Deterrnination of Particztlate Enaissions fr•otr: Stationary Sonrces", in conjunction with EPA Method 26A,

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5.0 SAlYIPLING RESULTS On December 12, 2000, stack gas emission studies were conducted at Carolina Ceramics, Columbia, South Carolina. The results of this testing are found in Tables 5.1 through 5.4. TABLE 5.1 H dr v ogen Fluoride Emission Results Outlet to Fluoride Cascade Absorber Carolina Ceramics Columbia, South Carolina Test conducted: December 12, 2000 Test Time Air Sample

Volume dscm Stack Gas

Flow Rate (dscfm) Emission

Concentration HF mg/m 3 Emission Rate

(lb/hr) Run#1 1150-1303 1.0126 11,128.32 2.27 0.0946 Run #2 1325-1432 0.9917 10,732.49 2.52 0.1012 Run #3 1454-1558 1.0397 11,672.73 2.40 0.1048 Average 1 1 1.0147 1 11,177.85 2.40 0.1002 Calculatiens: 1. Lbs/hr= 1 Ib/454,000 mg x mg/m 3 x Std. Ft 3 /Min x m 3 /35.31 

### ft 3 x 60 min/hr. NOTE 1: Standard cubic feet per minute at 29.92 inches of ineroury and 68 degrees F. H2SO4 0.1N Blank = <1100 Micrograms HF D.I. Water Blank = <500 Micrograms Chlorine D.I. Water Blank = <1100 Micrograms HF NOTE 2: (<) Note = less than the detection limit for the method and/or instrument. TABLE 5.2 Chlorine Emission Results Outlet to Fluoride Cascade Absorber Carolina Ceramics Columbia, South Carolina Test conducted: December 12, 2000 Test Time Air Sample

Volume dscm Stack Gas

Flow Rate dscfm Emission

Concentration Chlorine mg/m 3 Emission Rate Ibs/hr Run#1 1150-1303 1.0126 11,128.32 <0.49 <0.020 Run #2 1325-1432 0.9917 10,732.49 <0.50 <0.020 Run#3 1454-1558 1.0397 11,672.73 <0.48 <0.020 Calculations: I.Lbs/hr = 1 lb/454,000 mg x mg/m 3 x Std. Ft 3 /Min x m 3 /35.31 ft 3 x 60 min/hr. NOTE 1: Standard cubic feet per minute at 29.92 inches of inercury and 68 degrees F. D.I. Water Blank = <500 Micrograms Chlorine O.IN Na OH Blank = <500 Micrograms Chlorine NOTE 2: (<) Note =1ess than the detection limit for the method and/or instrument.

H:\ADMINDAT %PLOTHRID\HGA\O116138I-Carolina Ceramics.doc DAVIS & FLOYD, INC.5.2 TABLE 5.3 Hydrop } en Chlorid e Emission Results Outlet Fluoride Cascade Absorber Carolina Ceramics Columbia, South Carolina Test conducted: December 12, 2000 Test Time Air Sample

Volume dscm Stack Gas

Flow Rate (dscfm) Emission

Concentration HCI mg/m 3 Emission Rate

(lb/hr) Run#1 1150-1303 1.0126 11,128.32 2.37 0.0987 Run #2 1325-1432 0.9917 10,732.49 2.42 0.0912 Run #3 1454-1558 1.0397 11,672.73 2.31 0.1010 Average 1 1 1.0147 11,177.85 2.36 0.0987 Calculations: 1. Lbs/hr = 1 Ib/454,000 mg x mg/m 3 x Std. Ft 3 /Min x m 3 /35.31 0 x 60 min/hr. H2SO4 0.1N Blank = <1000 Micrograms HF D.I. Water Blank = <1000 Micrograms HF NOTE 1: Standard cttbic feet per minute at 29.92 inches of inercury and 68 degrees F. NOTE 2: (<) Note =1ess than the detection limit for the metllod and/or instrument.

e TABLE 5.4 _ Part ~ ate Emission Results Outlet Fluoride Cascade Absorber Carolina Ceramics Columbia, South Carolina Test conducted: December 12, 2000 Test Time Air Sample

Volume dscf Stack Gas

FlowRate (dscfm) Particulate Emission

Concentration Grains per SCF Emission Rate (Ib/hr) Run#1 1150-1303 35.7616 11,128.32 0.0127 1.2158 Run #2 1325-1432 35.0227 10,732.49 0.0133 1.2257 Run #3 1454-1558 36.7178 11,672.73 0.0101 1.0071 Average 35.8340 11,177.85 0.0120 L1495 a 7 F 52 4'%@ftY ~s~~ e tct o

~ Y,%Ffza. , ~~ . 5 7< , q Ii, ~,~ NOTE: Standard cubic feet per minute at 29.92 inches of inercury and 68 degrees F.

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POST OFFICE DRAWER 428 GREENWOOD, SOUTH CAROLINA 29648

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### L FOR:CAROLINA CERAMICS TEST METHOD:EPA METHODS 5& 26A LOCATION:COLUMBIA, SC SAMPLE DATE:12-12-00 SOURCE:FLUORINE CASCADE ABSORBER DAVIS &FLOYD, INC. JOB#:61381.00

% CO2 N/A N/A N/A N/A 

### % 02 N/A N/A N/A N/A % CO N/A N/A N/A N/A % N2 N/A N/A N/A N/A Dry molecularweight (MD) 29.00 29.00 29.00 29.00 Final impinger volume (VF) 490.0 488.0 490.0 489.3 Initial impinger volume (VI) 400.0 400.0 400.0 400.0 Silica gel vol. increase (VS GEL) 7.0 7.0 6.0 6.7 Total moisture collected (VIC) 97.0 95.0 96.0 96.0 Total moist. collected (VM STD) 4.5784 4.4840 4.5312 4.5312 Stack gas moist.content (B WO) 11.350 11.350 10.985 11.228 Meter dry gas volume (VM) 36.400 36.206 38.223 36.943 Barometric pressure (P BAR) 29.70 29.70 29.70 29.70 Dry gas meter temp (TM) 75.1 83.4 87.4 82.0 Dry gas orifice pressure (DELTA) 1.412 1.348 1.505 1.421 Meter dry gas volume (VM STD) 35.7616 35.0227 36.7178 35.8340 Stack gas moist.content (B WO) 0.1135 0.1135 0.1098 0.1123 Wet molecular weight (MS) 27.7516 27.7515 27.7917 27.7649 Pitot coefficient (CP) 0.84 0.84 0.84 0.84 Avg stack gas temp (TS AVG) 333.4 338.3 341.3 337.6 (AVG SQ/R DELTA P) 0.3578 0.3461 0.3759 0.3599 Static stack pres. (STATIC P) -0.170 -0.170 -0.170 -0.170 Pressure of stack (PS) 29.6875 29.6875 29.6875 29.6875 Stack gas velocity (VS) 25.2141 24.4655 26.5993 

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# ~ e(. 25.4263 Cross-sectional stack area (A) 12.5664 12.5664 12.5664 12.5664 Stack gas flow (QS STD CFM) 11128.3284 10732.4958 11672.7397 11177.8546 Stack gas flow (QS ACFM) 19010.9742 18446.5414 20055.4165 19170.9773 Wet bulb temp (WB/T) N/A N/A N/A N/A Particulate gain (MN) 29.6000 30.3000 .24.0000 27.9667 Particulate concent. (C/S) 0.0127 0.0133 0.0101 0.0120 C/S @%12 CO2 N/A N/A N/A N/A Particulate emission rate (CS) 1.2168 1.2267 1.0071 1.1495 Total Sampling Time (TIME) 60.0 60.0 60.0 60.0 Nozzie diameter (DN) 0.3440 0.3450 0.3400 0.3430 Area of nozzle (AN) 6.4542E-04 6.4918E-04 6.3050E-04 6.4170E-04 PeCcent isokinetic (i) 104.32 105.32 104.53 104.72 

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