Brier-... Pl•.hl- •- k.:ilh PSOI 

ENTEC Services 

Pollution Control System Evaluation and Source Emissions Testtng 

October 3, 2005 

Mr. John Jensen 

Belden Brick Company 

475 Dover Road 

Sugarcreek, OH 44681 

Re: RATAJCompfiance Testing for Gaseous Emissions 

Brick Plant No. 3 Tunnel Kiln 

Sugarcreek, Ohio 

Entec Project No,: 25126 

Dear Mr. Jensen, 

Please find the attached three copies of the RATA/complance emissions testing for the 

Brick Plant No, 3 Tunnel Kiln performed at your fact•y on August 24, 2005. 

VVe appreciate the opportunity to perform this project for you and hope to be of 

assistance to you in the future. If you have any questions please cal 205/491-6676. 

Sincerely, 

Entec Services, Inc. 

Erik Groth ( 

Project Leader 

Commerce Avenue Hueytown, Alabama 35023 Phone: (205} 491,,6676 Fax (2•5) 49t-66'•4 

•.entecserv|ces,com 
£NTEC Services 

Pollution Control System Evaluation and Source Emissions Testing 

October 21, 2005 

Mr. John Jensen 

Belden Brick Company 

475 Dover Road 

Sugarcreek, OH 44681 

Re: Compliance Testing for Gaseous Emissions 

Brick Plant No, 3 Tunnel Kiln 

Sugarcreek, Ohio 

Entec Project No.: 25126 

Dear Mr. Jensen, 

Please find the attached copy of corrected sheets. Please insert them into your copy of 

the report, 

We appreciate the opportunity to perform this project for you and hope to be of 

assistance to you in the future. If you have any questions please call 2051491,6676. 

Sincerely, 

Entec Services, Inc. 

Efik Groth 

Project Leader 

Commerce Avenue Hue•owr•, Atabama 3502:• Phone: (205) 49t-6676 Fax (205) 49%6514 

www.en•ecservtces,com 
Entec Sewic , Inc. 

16 D Commerce Avenue 

Hueytown; Alabama 35023 

Telephone: (205) 491-6676 

Fax: (205) 491•14 

Results of the August 24, 2005 

RATA/Compliance Testing for Gaseous Emissions on the 

Brick Plant No. 3 Tunnel Kiln located in 

Sugaecreek, Ohio 

Facility Permit No. 06-79-00-0118, ID No. P301 

Submitted to: 

Belden Brick Company 

475 Dover Road 

Sugarcreek, Ohio •681 

Attention: Mr. John Jensen 

Entec Project No. 25126 

Completed By: 

Er•Groth 

Project Leader 

Report Submitted: October 3, 2005 

Reviewed By: 

Tom Lotz Sr. 

QNQC Manager 

hereby certify to the best of my knowledge all field sampling and laboratory ana•sis performed 

for this report Is authentic and accurate. It has been checked for completeness and accuracy. 
Belden Brick Company 

Table,of Conten•,,, 

Executive Summary 

Compliance Emissions Summary 

Relative Accuracy Test Results 

Sulfur Dioxide 

Nitrogen Oxides 

Carbon Monoxide 

Hydrogen Chloride 

Hydrogen Fluoride 

RATA Emissions Summary 

Detailed Test Results 

Sampling Procedures 

Location of Test Ports 

Diagram of Sampling Train 

RATA RM with System Drift and CEM's Field Data 

Volumetric Flow Field Data 

Quality Assurance t Quali• Control Procedures 

QA I QC Checklist 

Orifice Check and Temperature Check 

Fydte / Oreat Standardization 

Equipment Calibrations 

Nomenclature and Test Calculations 

Pa•e No. 

3 

5 

6 

7 

8 

9 

10 

11 

12 

16 

19 

2O 

21 

93 

111 

115 

116 

117 

118 

131 
Executive Summary 

Entec Services, Inc. was retained by Belden Bdck Company to perform a RATA on the 

CEM unit and compliance gaseous emissions testing on Brick Plant No. 3 Tunnel Kiln 

located in Sugarcreek, Ohio. The control devices for the kiln are a dry scrubber and a 

baghouse. The Opsis CEM is composed of two analyzers. One analyzer uses an 

infrared (IR) detector and the other used an ultraviolet (U• detector. The IR detector 

analyzes the gas stream for NOx, CO and SO2. The UV detector measures HCt and 

HF. Both analyzers shoot the IR/UV across the stack to let the gas combine with the 

projected light source. A detector at the other side of the stack picks up the light source 

influenced by the gas stream and transmits via fiber optic cable the signal to be 

processed by a interferometer located with the signal processing equipment in the 

cabinet. This "spectra" is then turned into a direct ppm measurement. 

Mr. Erik Groth and Mr. Tommy Lotz, Jr. of Entec Services, Inc conducted the testing on 

August 24, 2005. Mr. John Jensen was present from Betden Brick and to coordinate 

testing with control room activities. Mr. Todd Brown from the State of Ohio 

Environmental Protection Agency observed these tests. 

The fourth RATA run failed the spike and recovery procedure for the reactive gases and 

was considered invalid for the HCI and HF compounds. Ten 30-minute •TAs were 

performed. Due to the fourth RATA being incomplete, RATAs 1-3, 5-7 were used for 

the compliance tests. No other difficulties were encountered in the field collection of the 

samples or in the laboratory analysis of the samples by Entec Services, Inc. 

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

of each paired test run compared to the maximum emission limits set forth by the State 

of Ohio Environmental Protection Agency. Tests results indicate the average 

gaseous emissions are below the limits set forth by the State of Ohio EPA for 

Facility Permit No. 06-79-00-01t8, Facility Source Identification No. P301. 
The RATA te• summaries on the following pages give a summaw of the CEM's 

•tcUlated emissions, referen• method •lculated et•issions and the cai•ulated 

relative ac•ura• •or the CEils emissions: Tekt results indicate that ,the RATA 

results are below•e ltmi• for so2, NOx, CO, HF & HCI assetfolloW the Codeof 

Fede•| Regulations (CFR)4OPa• •0, AppendS: B, and ;Perfo•anCe: S•ciflcatlon 

6 and 
The RATA test summaries on •e following pages give a summary of the GEM's 

calculated emissions, reference method calculated emissions and •the calculated 

relative accuracy for •the GEM's emissions, Test. results indicate that the •-RATA 

resul• am •low the limi• for 802, •HF & HCi and above the limits for NO• CO as 

set forth by the. Code of Federal Regulations (CFR) 40 Part 60, Appendix B, and 

Performance Specification 6 and 

m 

"I 
:! 

Reletive Test Ult• 












SOURCE OWNER: 

PLANT L•:X:ATION: 

SOURCe(S) 

SOURCF•S) CONDITION: 

8OURCE{8) SHAPE: 

SOURCE PERMIT NLI•BER: 

TEST PERFOPJ•ED: 

REFERENCI• M•OD TESTS: 

PROJECT MANAGER 

ENVIRONMENTAL Ahta•.¥ST *PROJECT LEADER 

OWNER• REPRE•NTATIVE: 

RULJNG.AGENCY: 

RULING AGENCY REPRESENTATWE: 

DATES TESTS CON[IJCTED: 

ENTEC P•ECT NUMBER: 

Entec Services, Inc. 

•URCE.OVERVIEW 

•Plml,Tmne• • NO. 3 

EPA Me• 

F.PA Method •6/15 

EPA Me•od • 6/15 

EPA Method 

£•PA, Method 




Procedures 

The relative accuracy test results and the emission tests were determined using EPA 

Methods 1-4 CFR Title 40, Part 60, Appendix A; Method 320 CFR Title 40, Part 63, 

Appendix A; and CFR Title 40, Part 60, Appendix B performance specification 6 for flow 

rates, and performance specification 15 for all gases. The calibration and quality 

assurance procedures of EPA CFR 40 Part 60 Appendix A, Part 63 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, 2004, of each method (as described in 

the Federal Register) was used, 

To satisfy the certification requirements for the CEMS data accuracy assessment of the 

applicable performance specifications in 40 CFR 60, Appendix B, the relative accuracy 

test must have a minimum of nine test runs. If more than 9 test runs are performed a 

maximum of three sets of the test results may be rejected so long as the total number 

of test results used to determine the relative accuracy is greater than or equal to nine. 

However, all data must be reported including the rejected data. The relative accuracy 

performance specification of the CEM'S must be no greater than 20 percent of the 

mean value of the reference data in units of the emission or 10 percent of the 

applicable standard, which ever is greater. 

Stack Gas Volumetric Flow 

The velocity of the gas stream was determined according to EPA Reference Method 1 

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

sampling point 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, 

A 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 and oxygen concentrations were determined using EPA Reference 

Method 3 (Fydte Method). A sample of the flue gas was extracted from the gas stream 

during each test. These samples were analyzed with a Fyrite gas analyzer. The 

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

dioxide content and the measured stack gas temperature. 

Moisture Content 

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

measuring the amount of condensed moisture in the stainless steel condenser and 

silica gel impinger in the sampling train as described in EPA Reference Method 4 at the 

completion of the first test. This was then compared to the Temet DX 400 FT-IR to 

show the accuracy of the measurement of moisture with FT-IR. Each test thereafter the 

Temet DX 4000 FT-IR was used to measure the moisture content. 

Emissions Measurements 

Emission measurements for NO×, SO2, CO HCI, and HF were performed using the 

Temet DX 4000 FT-tR in accordance with Performance Specification 6 and 15. Ten 30- 

minute runs were performed for the RATA. Nine of these runs satisfied the emissions 

portion of the test as per Performance Specification 6 and 15• Spike and recoveries 

were performed before and after each run to validate the accuracy of the analyzer and 

sampling system to correctly measure reactive compounds (HCI, HF). This spike and 

recovery technique was performed as specified in Method 320. In between each run a 

known value of NO2 and NOx were sent up the sample line and measured to insure the 

accuracy of the analyzer to measure NO× as per the request of the OHIO EPA. A total 

of 10 three-minute samples were collected per each 30 minute run. The sampling 

system turned over the cell volume 12 times per three-minute sample. This flow rate 

satisfied the measuring time/rate as set by performance specification 15. 
Entec Services, inc 

t6 D Commerce Ave. Hueytown• AL 35023 

STACK O.AWING & •RSE POINT •CATION 

Client: Belden Brick 

Source: Bdck Plant Tunnel Kiln No. 3 

Type of Traveme: VelOCity (V) or Particulate (P): 

Stack Diameter, tn•hes: 43 

Stack Height, fee• 60 

Star, k PropertY: Inche• 

Job No." 25•26 

input By: Tommy 

Upstream Distudmmce: 120.0 

Downstream Disturbance: 420.0 

V Port Type Flange Port Diameter 

Sta•k Area. Ft•: 

Numbe• of Ports: 

Duct D|ameter• Lmtgth of Po• 

2.•0 To•l N•r •Tmv•e P•: 

8.75 Num•r • P•n• •r dl•r: 

4,0" 

2 

48.0 INCHES 

120.C •.CHES 

420.( K•HES 

FLOW 

Inside Stack Outside Nipple 

Po, ,n,t N¢• inches Inche• 

IE 2.1 9.6 

2 7,0 14,5 

4 33.8 4t .3 

5 41.0 •5 

6 45•9 53,4 

RATA 

8.2 

24.0 31,5 

3•.8 47.3 

AdjuM•l poin• diameter > 24" no point clout than 1.0 inch 

Adjusted points dtameiar <_ 24" no point clo•m" than 0,S inch 

Stack Dismetem between 12-24 inches minimum points am8 

4 points per port if the 8 f 2 diameters downstream and 

upetmam crif•da is met, 
FT-IR Sampling Train 

He.ted 

•nium 

Heated '"'1 Teflon 

Coated 

Filter Box 

Heated CalibrationGae 

Line 

Heated Teflon Line 

SP-4000 

Heated 

Pump 

Assembly 

Data 

Acquisition 

Communication Li•s 

N• Spike!