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,

comEntec 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 0SOURCE

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 123
26A26AENTEC 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 in. Hz0 Pg

Y -3.00 0.84 0.907 1.877 in. H20

0.907 -3.10 0.84 0.907 1.877 1 377 -3.03 0.840.907 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 2.0497.210.016.04.O 0.397 356.185.4 AHW•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 1.9397.911.6t7,03.0 0.386 356.883.2 (in. H20) u2

mg Total Hydrogen

Chloride collected,

mg Total Hydrogen

Fluoride collected,

mg

coz 103.5 1.8983.812,916.53.5 0.380 355.888.0 (sqrt AP)•vg

HCLHF 25.6 103.3 1.9593.011.516.53.50.388 356.3 85.526.2Sampling ProceduresThe

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.

13Entec 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