Pollution Control System Evaluation and Source Emissions Testing 

August 24, 2006 

Mr. Frank Porter 

Borai Brick 

P.O. Box 1178 

Columbus, Georgia 31902 

Re: Compliance Emissions Testing 

Kiln DIFF System Inlet I Outlet Exhaust 

Boral Brick Union City, Oklahoma 

Entec Project No.: 26165 

Dear Mr. Porter, 

Please find the attached three copies of the compliance emissions testing for the Kiln 

Diff system Exhaust and Inlet performed at your facility on August 8, 2006. 

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 205/491-6676. 

Sincerely, 

Entec Services, inc. 

aL_Y• 

Beane 

nager 

16-D Commerce Avenue Hueytown, Alabama 35023 Phone: (205) 491-6676 Fax (205) 491-6614 

www, entecservices, com 
Entec Services, |nc 

16-D Commerce Avenue 

Hueytown, Alabama 35023 

Telephone: (205) 491-6676 

Fax: (205) 491-6614 

Results of the August 8, 2006 

Compliance Emissions Testing on Kiln DIFF System 

inlet and Exhaust Stack at the 

Boral Brick Facility in 

Union City, Ok|ahoma 

Submitted to: 

Bora• Brick 

P.O. Box 1178 

Columbus, Georgia 31902 

Attention: Mr. Frank Porter 

Entec Project No. 26165 

Completed By: 

TommyLo Jr. I Project 

Report Submitted: August 24, 2006 

Reviewed By: 

: Tom"-L ,•Sr. 

Technical Services Manager 

hereby certify to the best of my knowledge all field sampling and laboratory analysis performed for 

this report is authentic and accurate. It has been checked for completeness and accuracy. 
Executive Summary 

Boral Brick, located in Union City, Oklahoma, was retained Entec Services, Inc. to 

perform emissions testing on the Kiln DIFF system (inlet duct and exhaust stack). Mr. 

Tommy Lotz, Jr., Mr. Joseph Lotz, and Mr. Art Otero of Entec Services, Inc. conducted 

the testing on August 8, 2006. Representing Boral Brick was Mr. Frank Porter who 

coordinated testing with the control room production activity. 

No difficulties were encountered in the field collection or in the laboratory analysis of the 

samples by Entec Services, Inc personnel. 

The emissions from the kiln are controlled by a DIFF system. The particulate emissions 

test summaries on the following pages give a detailed analysis of each test run. The 

reduction efficiency for the HCI was 68.85% and the reduction efficiency for the HF was 

98.97%. 
0 0 

0 0 

0 
SOURCE OWNER: 

PLANT LOCATION: 

SOURCE(S) NAME(S): 

SOURCE(S) CONDITION: 

SOURCE(S) SHAPE: 

SOURCE PERMIT NUMBER: 

TEST PERFORMED: 

ADDITIONAL TEST REQUIREMENTS: 

REFERENCE METHOD TESTS: 

PROJECT MANAGER 

ENVIRONMENTAL ANALYST-PROJECT LEADER 

OWNER'S REPRESENTATIVE: 

RULING AGENCY: 

DATES TESTS CONDUCTED: 

ENTEC PROJECT NUMBER: 

Entec Services, Inc. 

SOURCE OVERVIEW 

Boral Brick 

Union City, Oklahoma 

Kiln DIFF Exhuast 

Compliance Emissions Testing 

Circular 

2004-210-C 

Hydrogen Chloride and Hydrogen Flouride 

Minimum 30 dscf 

Sample Location 

Volumetric Flow 

Molecular Weight 

Moisture Content 

Hydrogen Chloride 

Hydrogen Ruoride 

Mr. Tommy Lotz, Jr. 

Mr. Joseph Lotz 

EPA Method 

EPA Method 

EPA Method 

EPA Method 

EPA Method 

EPA Method 

Mr. Frank Porter 

Oklahoma Department of Environmental Quality 

08108106 

26165 

1 

2 

3 

26A 

26A 
ENTEC Services, Inc. 

16-D Commerce Ave. Hue/town, Alabama 35023 

CALCULATED TEST DATA 

Client: Boral Brick 

Source: Kiln DIFF Exhuast 

Description Formulas 

Run Number 

Test Date 

Time Began-Ended 

1, Stack Pressure P•, P,•113.6 

2. Meter Pressure P•f •H 113.E 

3. Standard Meter Volume 17.64- Y" (VnJTm}* (P=•, •H t3,• 

4a. Standard Volume of Water Vapor Condensed =o.o4706,w• 

4b. Standard Volume of Water Collected in Silica Gel =o.04T15"W=• 

5, Moisture Fraction 

9. Molecular Weight Of Stack Gas, dry basis 

10. Motecutar Weight Of Stack Gas, wet basis 

•I 1. Average Stack Gas Velocity 

12. Stack Gas Flow @ Stack Conditions 

0,3z*(oz}+ 0.44-(c0•)+0,2so(10o.(0=)-(co2)) 

8s.49"c•*(sqrt •.P)=•*SQRT((T=) 

13. Stack Gas Row @ Standard Conditions 

14. Stack Gas Flow @ D•/Standard Conditions 

14b. Hydrogen Chloride concentration @ Std.Con•.,Gralns/Cu.Ft. 

t4b. Hydrogen Fluoride concentralion @ Std.Cond,,Grains/Cu.Ft, 

•b. Hydrogen Chloride emissions, Ibs per hour 

=(0.01543"HFmq]/Q==< 

=(60,"/000}*HCLQ=m" Q•z= 

•Sb. Hydrogen Fluoride emissions, Ibs pe=" hou• 

22. Volume collected through nozzle 

24. Isoklnetic Sampling Rate, Pement 

=(60tT000)*HFQz•Q==• 

=T=IP=*[0.002669"V•÷ V•*Y' P,,•',,,] 

100*Vn 

Symbol Units 

Military Time 

in. Hg 

in. Hg 

dscf 

gtg.mole 

gfg-mele 

•,/s 

s•fm 

% 

Job No.: 26166 

Data Input By: Tommy Lotz, Jr, 

Calculated Data 

08108106 08/08/06 08108108 

1620-1722 

AVERAGE 

1300-1403 1440-1542 

28.88 28.88 28.88 28.88 

28.96 28.97 28.97 28,97 

30.944 32.282 31.939 31.722 

3.431 4.499 3.257 3.729 

0.302 0.321 0.288 0.303 

0.1076 0.1299 0.0999 O.1125 

29.280 29.280 29.280 29.280 

28.066 27.815 28.153 28.011 

28.31 29.77 29.03 29.036 

27,016 28,404 27,702 27,707 

17,514 18,398 17,963 17,959 

15,629 16,008 16,169 15,935 

0.008676 0.0•0• 

-0.00001 

0.0•365 0.008692 

0.00014 0.00011 

1.162 1.148 1,252 1,187 

0.019 0.015 0.001 0.012 

0.00009 

53.491 

100.13 

57.283 54.722 55.165 

101.99 99.90 100.67 

Post Meter Orifice Cal. (EMC ALT-00S Yqa) YD, 1.0112 1.0075 1.0009 1.0065 

% Oii't"erance, (Calibration must be within 6% of original Y-fa•tor} -2.08% 

Note: Indicates less than value, 0;02 mg is the detection limit of the analytical p•'ocedure and used fo.r emissions caiculations. 
ENTEC Services, inc. 

16-D Commerce Ave. Hueytown. Alabama 35023 

INPUT TEST DATA 

Client: 

Source: 

Boral Brick 

Kiln DIFF Inlet 

Field Data 

Run Number 

Test Date 

Symbol Units 

Job No.: 

Data input By: 

26165 

Tommy Lotz, Jr. 

Test Data 

2 AVERAGE 

Time Test Run Began Ended 

Sampling Time 

Stack Area 

Barometric Pressure 

Stack Static Pressure 

Pitot Tube Correction factor 

Meter Correction Factor 

Meter Delta H @ 

Military Time 

minutes 

08•8•6 

1300-1405 

6O 

08/08/06 

1440-t542 

6O 

08•8•6 

4620-1722 

60 6O 

F t• 15,904 15.904 15.904 

in. Hg 28.88 28.88 28,88 28.88 

-3.00 

0.84 

Pg in. Hz0 

Y 

-3.00 

0.84 

0.907 

in. H20 1.877 

0.907 

-3.10 

0.84 

0.907 

1 377 1.877 

-3.03 

0.84 

0.907 

1.877 

103.0 

)zzle Diameter D. inches 0.375 0.375 0.375 0.375 

Meter Volume v,, dcf 53.740 53.829 53.629 53.733 

F 

2.04 

97.2 

10.0 

16.0 

4.O 

0.397 

356.1 

85.4 

AH 

W•mp 

Meter Temperature 

Avg. Orifice Delta H 

Impingers Weight Gain (Moisture) 

Silica Gel Impinger Weight Gain (Moisture) 

Oxygen Concentration, dry basis 

Carbon Dioxide Concentration, dry basis 

Avg. Sq. Rt. of Delta P 

Stack Temperature 

in. Hz0 

grams 

grams 

103.4 

1.93 

97.9 

11.6 

t7,0 

3.0 

0.386 

356.8 

83.2 

(in. H20) u2 

mg Total Hydrogen Chloride collected, mg 

Total Hydrogen Fluoride collected, mg 

coz 

103.5 

1.89 

83.8 

12,9 

16.5 

3.5 

0.380 

355.8 

88.0 

(sqrt AP)•vg 

HCL 

HF 25.6 

103.3 

1.95 

93.0 

11.5 

16.5 

3.5 

0.388 

356.3 

85.5 

26.2 
Sampling Procedures 
The sampling probe was placed at each sampling point to provide a total sampling time 

of sixty (60) minutes. The gases were drawn through a glass nozzle attached to a 

heated glass lined probe. The probe was maintained at the proper settings to obtain an 

exit temperature of greater than 248 o F during sampling. The gases then proceeded 

through borosilicate glass filter holder, with a Teflon frit filter support through a Teflon 

filter to remove particulate matter. The filter was maintained at a temperature of greater 

than 248 0 F. These temperatures were recorded at each point on the field data sheets. 

The gases were then scrubbed through a series of four pre-weighed 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 (acid) solution and the third and fourth impingers contained 

approximately 100 ml of a 0.1 N NaOH (alkaline) 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 clean and cool gases then 

entered the meter box where the 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. 

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 gel 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. These containers 

were clearly marked and transported to the laboratory for analysis. 

13 
Entec Services, lnc 

16 D Commerce Ave. Hue•town, AL 35023 

STACK DRAWING & TRAMERSi= POINT LOCATION 

Client: Boral Brick Job No. 

Source: Kiln DIFF Inlet Input By: Tommy Lotz, Jr. 

Type of Traverse: Velocity (V) or Particulate (P): P Port Type Nipple Port Diameter 4.0" 

Stack Diameter, inches: 54 Stack Area, Ft•: 15.904 

Stack Height, feet: 25 Number of Ports: 2 

Stack Properties: Inches Duct Diameters Length of Port, inches: tt,00 

Upstream Disturbance: 3%0 0.57 Total Number of Traverse Points: 24 

Downstream Disturbance: 466.0 8.63 Number of Points per diameter: 12 

54.0 INCHES 

Inside Stack Outside Nipple 

Point No. Inches Inches 

1 1.1 12.1 

2 3.6 14.6 

3 6.4 17,4 

4 9.6 20.6 

5 13.5 24.5 

6 19.2 30.2 

7 34.8 45.8 

8 40.5 51.5 

9 44.4 55.4 

10 47.6 58.6 

11 50.4 61.4 

12 52.9 63.9 

Adjustsd points diameter > 24" no point closer than 1.0 inch 

Adjusfad points diameter <_ 24" no point closer than 0.5 inch 

Stack Diameters between 12-24 inches minimum points are 8 

4 points per port if the 812 diameters downstream and 

upstream criteria is met. 

15