# TEST

RE PO RT for 

# Han so n Bri ck Columbia, SC

Prep ared

f or : Ha nso n B ric k Eas t, LL C dba H ans on Bri ck

510 0 B ric kya rd R oad Co lu mbi a, S C 292 03 Prep ared

by:

Ai r-Tech E nvi ronmen tal

, LL C P. O. Bo x

12 353 Re sea rch Trian gle Pa rk, N C 277 09-2 353

(919 ) 54 4-63 38 Tes t D ate: October

5, 2006Ai r- TechE

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, LL C pe rson nel and i s a true rep rese ntati on of the resu lts ob tai ned from the sampl in g program for Bri ck Ki ln s ES-P4K1 and E S-P 4K2 a t P la nt 4 at the Co lu mbi a, S C faci li ty . The sampl in g and an al ytic al me th o d s w e re p e rfor me d i n a cc o rd a n ce w i th p ro ce d u re s a p p ro v e d b yt h e S ta te o f S o u th Ca rol in a.

T ea m Le ad er: M i c h a e l W . H a rtm a n , P rin c i p a l S c i e n ti s t D a te
R evi ew er: D a rr e l l H . D o e rle , S e n i o r S ta ffS c i e n ti s t D a teAi r- TechE

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### TA BLE OF CONTENTS Pag e
1
. 0 I N T R O D U C T I O N
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2
. 0 R E S U L T S S U M M A RY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2
. 1 H F a n d H C l S a m p l i n g R e s u l t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2 .2 P a rt i cu l a te M a tt e r S a mp l i n g R e su l ts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3
. 0 S A M P L I N G A N D A N A L Y T I C A L M E T H O D S
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4 .0 QU A L ITYA S S U RA N C E / QU A L ITYC ON TR OL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
T able s T a b l e 1
. H F a n d H C l R e s u l t s S u m m a ry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 T a b l e 2
. M e t h o d 5 R e s u l t s S u m m a ry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 T a b l e 3
. Q A

S u m m a ry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Figu res Fig ure 1 Proc ess Schem atic, Hanson Brick(Columb ia, SC)
. . . . . . . . . . . . . . . . . . . . . . 6 F i g u re 2 M e t h o d 2 6 A S a m p l i n g T ra i n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Ap pen dices Ap pen di x

A Fi el d D ata Sh eets an d R un Su mmarie s Ap pen di x

A .1 Inl et Ap pen di x

A .2 Outle t A p p e n d i x

B A n a l yti ca l R e p o rt Ap pen di x

C M eter Ca li brati ons Ap pen di x

D Pro ces s D ocu mentati on Ap pen di x

E Exampl e C al cul ati onsAi r- TechE

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### 1.0 INT ROD UC TION On O cto ber

5, 2006, Air-Tech Environ m ental performe d sam pling at the Han son Brick Col umbia, SC faci li ty

per Ai r Per mit No. TV- 1900- 0010. Emi ss ion s t est ing was condu cte d to demonst ra te c ompli ance w it h the emi ss ion l imi ts and ope ra ti ng l imi ts that are l is ted i n N ESH AP, Subpar t J JJ JJ ( the M AC T) for

br ic k k il ns eq uip ped w it h a D LA. Tw o k il ns, ES- P4K1 and ES -P 4K2, at P lan t 4 w ere tes ted a t t he C olu mbia facil ity . These two k il ns ex haust s a re ducted t o a c ommon sc ru bber ( a dr y l ime absor ber

or DLA ), to re mov e hydrog en fluor ide ( HF ) emis si ons from the ex haustst re am. S ampli ng w as con duct ed a t the ex hau st stack of the DLAto chara cteriz e em issions of HF, hy drog en c hlo ri de ( HC l) , and fil terabl e par ti cul ate matter

( PM ) uti li z ing the sampl ing procedu re s o f Meth od 26A
. Addi ti onal ly , M ethod 26 s ampleswere c oll ect ed atthe inl et to t he D LA i n order

to deter mine the D LA remov al eff ic ien cy for H F and H Cl
. A summar y of the resul ts is present ed i n the tabl e bel ow . These resul ts ind ic ate H anson Brick is ope rating Plant 4 in com pliance w ith the MACT requireme nts. This repor

t present s t he resul ts of the s ampli ng i n Secti on 2. A desc ri pti on of the sam pling location s and the m eth odo logies emp loyed in emission s characte riz ation s are cont ain ed i n Secti on 3. Se cti on 4 present s a n as ses sment of the q ual ity co ntrol measures tak en dur ing the per formance of thistes t prog ra m.

Ma ssRa te
D RE ( %) lb/hr lb/ton Inlet Outlet Inlet Outlet P M N /M 0 .8 2 N /A 0 .0 3 7 N /A b H F 1 0 .3 5 0 .8 5 0 .4 7 0 0 .0 3 9 9 1 .8 H C l 0 .6 3 0 .3 4 0 .0 2 8 0 .0 1 5 4 5 .4
N M = notm easur ed aN /A = n o t a p p lic a b le bAi r- TechE

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### 2. 0 RESULTS SUM M A RY Three tes t r uns w ere c onducted for the deter minat ion of emis si on rates for e ach of the com pou nds o f

interest. Testsumm aries group ed b y comp oun ds of

interest a re present ed bel ow . Efforts w ere made, suc ces sfull y , to c oll ectal l sampl es dur ing st eady product ion rates of a s ing le ty pe of product
. The br ic k p ro duct ion rate d ur ing the tes ti ng av erag ed 11. 01 to ns per hour per ki ln, tot ali ng 22.0 2 ton s p er hour
. Press ure drop 2 across the DLA

av erag ed 1. 018 “ H O for the t estper iod s. The l imes tone feed rat e during the co mp liance te st w as ma intain ed a t 90 po und s per hou r. 2.1 HF and H Cl Sampling Res ults Sam ples w ere collecte d simu ltane ously at the DLA inle t and ex hau st for all three te st ru ns. A summar

y of the resul ts of the H F and H Cl flue g as conc entrati ons and emis si on rates i s p re sent ed i n Tabl e 1. Al l tes ts did co mply w it h fiel d s ampli ng proce dure s pertain ing to samp le train op eratin g tem pera tures an d leak che cks. Fl ue g as conc entrati ons of HF were found to av erag e 157 ppm at the D LA i nle t and 13.5 ppm at the o utl et. These conc entrati ons y iel d massrates of HF thatav erag e 10. 4 lb/hr into the DLAand 0.85 lb/hr out . Th ese m easu reme nts sho w a remo v al ef

f iciency exceeding 91. 8% for HF. Fl ue g as conc entrati ons of HC l av erag ed 5. 1 and 2.9 p pm at the D LA i nle t and outl et g as streams, re specti v ely
. These c oncen trati ons y iel d massrates of 0.63 and 0.34 lb/ hr , a DR E of 45.4%
. Non e of the measurements i ndi cat e a s ig nific ant a mount of HCl to be p resen t in the f lue gas.

Table 1 . HF and HCl Results Summary - Pla nt 4

Run #/ Time Fl

ow ( ds c f m) Flue Gas Concentration Mass Rat e H F ( pp m) H Cl

( pp m) H

F ( l b/ hr ) H Cl

( l b/ hr ) D RE (

%)
I nl et Out

l et I nl et Out l et I nl et Out l et I nl et Out

l et l b/to n brick I

nl et Out

l et l b/to n brick HF HCl 1 10 40 -1 20 5 2 1 6 4 5 1 9 7 5 5 1 5 2 1 4 4 .3 2 .8 1 0 .2 0 .8 5 0 .0 4 0 .5 4 0 .3 2 0 .0 1 9 1 .7 4 0 .7 2 12 18 -1 32 4 1 9 0 1 6 2 0 1 6 5 1 5 8 1 3 4 .8 2 .9 1 0 .2 0 .8 4 0 .0 4 0 .5 7 0 .3 4 0 .0 2 9 1 .7 4 0 .8 3 13 37 -1 43 1 2 1 3 1 4 2 0 6 0 6 1 6 0 1 3 6 .3 2 .9 1 0 .6 0 .8 4 0 .0 4 0 .7 7 0 .3 5 0 .0 2 9 2 .1 5 4 .7 Av e ra g e 2 0 6 5 8 2 0 1 7 5 1 5 7 1 4 5 .1 2 .9 1 0 .4 0 .8 5 0 .0 4 0 .6 3 0 .3 3 0 .0 2 9 1 .8 4 5 .4Ai r- TechE

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, L LC Ha nson Br ick/C olumbi a T est Re por t (AT06 -039 6-HBC) Test D ate : 1 0/5 /20 06 - Page3 2.2 Partic ulate Sa mpling Results Par ti cul ate s ampli ng was per formed for the d eter minat ion of filt erabl e PM us ing p ro ce d u re s o f

Met h o d 5. Th e se res u lt s a re pre se n te d in T a b le 2. T h e ave ra ge conc entrati on of PM was found to be 0.00 48 g ra insper dr y st andard c ubi c foot (g r/dscf), rang ing from 0. 0025 t o 0.0 06 g r/dscf. These conc entrati ons y iel d emi ss ion rates th at range f rom 0 .43 to 1.0 3 lb/h r, and a v erage 0.8 2 lb/h r.

Table 2 . Method 5 Results Summa ry - Pla nt 4

Run # Tim e Co ncen tr ation (gr /ds cf) Flo w

(ds cfm ) Emi

ssio n Ra te (#/hr) Emi

ssio n Rate (lb /to n b rick) 1 1040- 1205 0. 0059 19755 0. 99 0. 045 2 1219- 1325 0. 0060 20165 1. 03 0. 047 3 1336- 1431 0. 0025 20606 0. 43 0. 020 Aver age 0. 0048 20175 0. 82 0. 037Ai r- TechE

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### 3. 0 SA M PLING A ND A NA LYTICA L M ETHODS The sampl es w ere c oll ect ed from t he ex haustof the b ri ck ki lns , a natural g as- fire d proces s o perati ng co nti nuous ly 24 h ours p er

day , s ev en days p er

week. There were no PM c on trol o f em i s s i on s from t he s e s ou rc es ; ac i d g as es were s c r ub be d i n a dr y l i me absor ber pr ior to ex haust
. A s chemat icof the p ro ces s e x hausti s c ontai ned i n F ig ure 1. Inl et s ampleswere c oll ect ed from a ci rc ula r duct64 i nchesi n di ameter
. Tw o s ampli ng por ts, pl aced at r ig ht an g les , prov ide d for acc ess for v elo ci ty trav erses . A to tal of 12 poi nts were s ampled for v elo ci ty measu re ments. A sc hemati c o f this tes t l ocat ion show ing sa mple poi nt l ocat ion on t he “ Trav erse Poi nt Lo cat ion F or m” has been appended w it h the tes t dat a. DLA ou tlet sam pling was con duct ed a t the ex hau st stack f rom a duct 59 .5 inch es in dia meter
. This sa mpli ng l ocat ion met t he req uirements of Me thod 1 al low ing a 12 -p oin t particu late m atte r test to be cond ucte d. A schem atic of this location on the “Traverse Poi nt Lo cat ion F or m” show ing poi nt pl acementhas been appended as w ell
. Three one hou r sampl es si mult aneous ly were c oll ect ed from e ach sampl ing l ocat ion
. Con cur re nt w it h the tes ti ng readi ng s o f DLA press ure drop were made a t t he faci li ty monit or , a photohe li c d ifferenti al press ure g aug e. These readi ng s were l og g ed instrum ent ally

at app rox ima tely 5 min ute intervals by facility mon itors. Sam pling was pe rforme d acco rding to the pro cedu res of Method 26A a t the outle t test loc ati on. These procedu re s e ntai l is oki neti c c oll ect ion of a par ti cul ate s ample follo w ed by collection of

acid gases in dilute so lution s of sulf uric acid. A schem atic of this sampl ing train i s c ontai ned i n F ig ure 2. N ote t hat t he c aust ici mping ers u sed for th e col lecti on of di atomi c h alo g ens w as not u sed. The flue g as sampl e was w it hdraw n throug h a g las s n ozz le int o a g las s p ro be. Par ti cul ate matter

was filt ered th ro ug h a h eated Tef lon fil ter and then entered th e imp inger portion of

the sam pling train. Th is impinger portion consiste d of two imp ingers cont ain ing 100 ml o f 0.1N sul furi c a ci d eac h foll ow ed by an e mpty

i mping er , t hen a si li ca g el cont ain ing i mping er us ed for final moi stu re co ll ect ion
. A ty pe S pit ot t ube and ty pe K ther mocoupl e were us ed to measu re v elo ci ty press ures and t emperatures at each sampl ing poi nt. A c ali brated dr y g as meter

was used to meas ure s ample v olu me. A c ali brated or ific e pl aced on th e meter outl et was used to s et s ample ra te. Inl et s ampli ng was condu cte d ac cordin g to the p ro cedures of Met hod 26. The no nis oki neti c M ethod 26 s ample w as col lected from three poi nts at the i nle t l ocat ion
.Ai r- TechE

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, L LC Ha nson Br ick/C olumbi a T est Re por t (AT06 -039 6-HBC) Test D ate : 1 0/5 /20 06 - Page5 W ith the ex cept ion of

not collect ing a particulate f raction at the DLA inlet, sam ple re cov er y resul ted i n the co ll ect ion of the fol low ing sa mple fract ion s.

• Acet one washe s, w ith brush ing, of those portion s of

the sam ple train upst re am of the fil ter
. • T he f ilter.

• T he su lf uric acid impin ger solutions an d w ate r r inses of all ex pose d glass surfaces d ownstream f rom th e f ilter to the inlet to th e silica g el impin ger.
• T he silica gel. Acet one washeswere dr ied dow n i n tared beak ers for the g ra v imet ri c d eter minat ion of w eig ht g ain
. This g ain , add ed to thatdete rmi ned for the t ared fil ters, made up the par ti cul ate t otal of the s ample. The t otal mass of PM co ll ect ed was div ide d by the sampl e v olu me to deter mine par ti cul ate c oncen trati on ( g r/dscf). This v alu e was mu ltiplied by flue g as f low rate to de term ine m ass em ission rate (lb/h r). Mass em issions w ere divided by productio n rates to dete rmine emission s in terms of brick product ion rates ( lb/ton)
. Compl ete e x ample cal cul ati ons as w ell as the anal yti cal and ru n dat a hav e been appended. The aci d matr ix

sa mples were anal yz ed for fluor ide and chl or ide i ons follo w ing the ion chrom ato graph y

ana lytical proced ures of Method 26A. The se an alyses y ielded liq uid conce ntrat ions for the ion s of interest (ug/m l). Conversions of ion conce ntrat ion to acid conc entrati on were made o n a o ne to one basi s. These aci d c oncen trati ons w ere the n converted to tota l mass of the com pou nd o f

interest co llected using the liq uid sam ple v olu me. Thi s t otal mass was then conv erted t o massrates for e ach sampl ing l ocat ion in fashio n similar to th e pa rticulate mat ter calculat ions. DLA rem oval ef f iciencies w ere cal cul ated based on t he c alc ula ted mas s rates of the c ompounds of int erestat the i nle t and out let
. Compl ete a nal yti cal su mmari es and example cal cul ati ons hav e been appended. Af ter not ing the posttest w eight gain, the silica gel was discarde d. T his w eight gain w as added t o tha t det er mined for th e restof the i mping er train pr ior

to sampl e recov er

y . The tota l w eig ht g ain of the i mping er train was attr ibu ted t o flue g as w ater v apor and used for f lue gas mo isture f raction calculatio ns (Metho d 4). Flue gas fixed gas analysis w as per formed on bag s c oll ect ed dur ing eac h tes t us ing the g ra b procedu re s o f Meth od 3 using an Orsat co mb ustion ana lyz er. Th ese d ata , alon g w ith the v elocity pressure and t emperature ( Me thod 2) dete rmi ned eac h s ample poi nt ( Me thod 1) dur ing the per formance of the i sok ine ti c s ampli ng were us ed to ca lc ula te flue g as v olu metr icflow rates use d in ma ss rate calcula tions.Ai r- TechE

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Figu re 1. Pro ces s S che matic, Ha nso n Bric kAi r- TechE

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Fi gu re 2 . Me th od 26A Sam pl in g TrainAi r- TechE

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### 4.0 QU A LITY ASSU RA NC E / QUA LITY C ONT ROL The Qual ity

As surance (QA) procedu re s req uired by the re ferenc e method olo g ies em ployed du ring the testing w ere strictly adh ered to during the p erforma nce o f this test prog ra m. S uch adherence ensures product ion of useful and v ali d dat a throug hout the course of the proje ct. An anal yti cal audi t s ample w as not p ro v ide d to Air-Techfor anal ysi s, therefore t he meas ures made as des cr ibe d bel ow co mpri se the a nal yti cal QA. Con trol cr it er ia for th ese measures are notsp eci fied i n the method. The Q A procedu re s d esc ri bed i n thi s s ect ion representan i nteg ra l par t of the ov erall sa mpli ng and ana lytical schem e. T he a ccept ance criteria, control limits, an d the results of these measures obtai ned dur ing thi s t est ing and anal ysi s a re su mmari z ed i n Tabl e 4. A b ri ef d is c u s s io n o f

t h e Q Am e a s u re s is p re s e n t e d b e lo w. QA meas ures tak en to prov ide so me ass ess ment of the q ual ity of sampl e c oll ect ion inc lud ed meas ures of sampl ing rate, and t he as ses sment of the ac curacy of metered gas volum es an d the integrity of samp ling train. Out let sam pling rates, asse ssed a s % is oki neti cs , met method c ri ter ia for al l tes t r uns. Therefore, any sa mple bia s c aused by non represent ati v e c oll ect ion of differi ng par ti cl e s iz es (e it her

par ti cul ate matter

or water drop l et s ) was w i th i n ac c ep ta bl e l i mi ts
. Th e dr y g as me te rs u s ed for

s am pl e v ol um e det ermin ation mee t me tho d criteria for accuracy. Post-test sam ple train lea k checks meet t he metho d c ri ter ia for al l tes t r uns. The anal yti cal measu re s o f QA meet the met hod c ri ter ia for ac etone pur ity , an ass ess ment of the Me thod 5 anal ysi s. The M ethod 26A an alyti cal QC reli es on per formance of an audi t t o be prov ide d at the d is creti on of the SC DH EC
. In ab senc e of suc h a s ample the a nal yti cal QA ass ess ment was made bas ed on the meas urements tabul ated in Table 4. These da ta s how thatthe anal ysi s s uffered no si g nific ant b ias due t o the reag ents or

the sampl e matr ix
. Al l dupl ic ate a nal ysi s s how a preci si on of measurement of ex ceedi ng 2% of the repor ted valu e for all measu re ments. The cal ibrati on l ine ar ity

i ndi cat es the resul ts w il l be ac curate reg ardle ss of w here the y fall on the c ali brati on c ur

v e.Ai r- TechE

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Su mma ry
C rite ria C o n tro l L im it R e s u lt Sa m pl i ng % I s o ki n e t i c s 1 0 0 ± 1 0 % I n l e t NA O ut l et 99. 2 - 99. 5% D r yG as M et erC al i br at i on ( M 26) 1. 00 ± 2 % I nl et 0. 9968 O ut l et 1. 0046 Pos t Test Cal i br at i on Che ck ( M 26 A) d y ± 5% I nl et 1. 0071 O ut l et 0. 9674 Sam pl e T r ai n Le ak R at e ( M 26A) <0. 02 cf m I nl et 0. 00 - 0. 00 O ut l et 0. 00 - 0. 00 A nal y t i cal Acet one Bl ank ( M 5) # 0. 001 wt % 0. 0000g / 788 H 2SO 4 Bl an k ( M 26 A) W at erBl an k ( M 26 A) re s u l ts HF ND H C l 0. 04 : g /m l a HF ND HCl ND M at r i x Spi k e Recover y N ot speci f i ed H F 104% N ot speci f i ed H C l 97. 3% D upl i cat e Anal y si s, I nl et ± 5% m ean H F 0. 1 - 0. 3% ± 5% m ean H C l 0. 1 - 0. 4% D upl i cat e Anal y si s, O ut l et ± 5% m ean H F 0. 0 - 0. 1 % ± 5% m ean H C l 0. 0 - 1. 1% C al i br at i on L i near i t y N ot speci f i ed H F R = 0. 9997 2 N ot speci f i ed H C l R = 0. 9994 2 Val ue f al l s between t he m et hod det ect i on l i m i t and l i m i t of qua nt i z at i on. a