TEST REPORT

for

Hanson Brick

Columbia, SC

Prepared for:

Hanson Brick East, LLC dba Hanson Brick

5100 Brickyard Road

Columbia, SC 29203

Prepared by:

Air-Tech Environmental, LLC

P. O. Box 12353

Research Triangle Park, NC 27709-2353

(919) 544-6338

Test Date: October 5, 2006
Air-Tech Environmental, LLC

Hanson Brick/Columbia Test Report (AT06-0396-HBC)

Test Date: 10/5/2006 - Page ii

Air-Tech Environmental, LLC

Report Certification

This report has been reviewed by the following Air-Tech Environmental, LLC personnel

and is a true representation of the results obtained from the sampling program for Brick Kilns

ES-P4K1 and ES-P4K2 at Plant 4 at the Columbia, SC facility. The sampling and analytical

methods were performed in accordance with procedures approved by the State of South

Carolina.

Team Leader:

Michael W . Hartman, Principal Scientist Date

Reviewer:

Darrell H. Doerle, Senior Staff Scientist Date
Air-Tech Environmental, LLC

Hanson Brick/Columbia Test Report (AT06-0396-HBC)

Test Date: 10/5/2006 - Page iii 

TABLE OF CONTENTS

Page

1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.0 RESULTS SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2.1 HF and HCl Sampling Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2.2 Particulate Matter Sampling Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3.0 SAMPLING AND ANALYTICAL METHODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4.0 QUALITY ASSURANCE/ QUALITY CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Tables

Table 1. HF and HCl Results Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Table 2. Method 5 Results Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Table 3. QA Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Figures

Figure 1 Process Schematic, Hanson Brick (Columbia, SC) . . . . . . . . . . . . . . . . . . . . . . 6

Figure 2 Method 26A Sampling Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Appendices

Appendix A Field Data Sheets and Run Summaries

Appendix A.1 Inlet

Appendix A.2 Outlet

Appendix B Analytical Report

Appendix C Meter Calibrations

Appendix D Process Documentation

Appendix E Example Calculations
Air-Tech Environmental, LLC

Hanson Brick/Columbia Test Report (AT06-0396-HBC)

Test Date: 10/5/2006 - Page 1

1.0 INTRODUCTION

On October 5, 2006, Air-Tech Environmental performed sampling at the Hanson Brick

Columbia, SC facility per Air Permit No. TV-1900-0010. Emissions testing was

conducted to demonstrate compliance with the emission limits and operating limits that

are listed in NESHAP, Subpart JJJJJ (the MACT) for brick kilns equipped with a DLA. 

Two kilns, ES-P4K1 and ES-P4K2, at Plant 4 were tested at the Columbia facility. 

These two kilns exhausts are ducted to a common scrubber (a dry lime absorber or

DLA), to remove hydrogen fluoride (HF) emissions from the exhaust stream. Sampling

was conducted at the exhaust stack of the DLA to characterize emissions of HF,

hydrogen chloride (HCl), and filterable particulate matter (PM) utilizing the sampling

procedures of Method 26A. Additionally, Method 26 samples were collected at the inlet

to the DLA in order to determine the DLA removal efficiency for HF and HCl. A

summary of the results is presented in the table below. These results indicate Hanson

Brick is operating Plant 4 in compliance with the MACT requirements.

This report presents the results of the sampling in Section 2. A description of the

sampling locations and the methodologies employed in emissions characterizations are

contained in Section 3. Section 4 presents an assessment of the quality control

measures taken during the performance of this test program. 

Mass Rate

DRE (%)

lb/hr lb/ton

Inlet Outlet Inlet Outlet

PM N/M 0.82 N/A 0.037 N/A b

HF 10.35 0.85 0.470 0.039 91.8

HCl 0.63 0.34 0.028 0.015 45.4

 NM = not measured a

 N/A = not applicable b
Air-Tech Environmental, LLC

Hanson Brick/Columbia Test Report (AT06-0396-HBC)

Test Date: 10/5/2006 - Page 2

2.0 RESULTS SUMMARY

Three test runs were conducted for the determination of emission rates for each of the

compounds of interest. Test summaries grouped by compounds of interest are

presented below. Efforts were made, successfully, to collect all samples during steady

production rates of a single type of product. The brick production rate during the testing

averaged 11.01 tons per hour per kiln, totaling 22.02 tons per hour. Pressure drop

across 2 the DLA averaged 1.018 “H O for the test periods. The limestone feed rate

during the compliance test was maintained at 90 pounds per hour.

2.1 HF and HCl Sampling Results

Samples were collected simultaneously at the DLA inlet and exhaust for all three test

runs. A summary of the results of the HF and HCl flue gas concentrations and

emission rates is presented in Table 1. All tests did comply with field sampling

procedures pertaining to sample train operating temperatures and leak checks.

Flue gas concentrations of HF were found to average 157 ppm at the DLA inlet and

13.5 ppm at the outlet. These concentrations yield mass rates of HF that average 10.4

lb/hr into the DLA and 0.85 lb/hr out. These measurements show a removal efficiency

exceeding 91.8% for HF.

Flue gas concentrations of HCl averaged 5.1 and 2.9 ppm at the DLA inlet and outlet

gas streams, respectively. These concentrations yield mass rates of 0.63 and 

0.34 lb/hr, a DRE of 45.4%. None of the measurements indicate a significant amount

of HCl to be present in the flue gas.

Table 1. HF and HCl Results Summary - Plant 4

Run #/

Time 

Flow (dscfm)

Flue Gas Concentration Mass Rate

HF (ppm) HCl (ppm) HF (lb/hr) HCl (lb/hr) DRE (%)

Inlet Outlet Inlet Outlet Inlet Outlet Inlet Outlet

lb/ton

brick Inlet Outlet

lb/ton

brick HF HCl

1

1040-1205

21645 19755 152 14 4.3 2.8 10.2 0.85 0.04 0.54 0.32 0.01 91.7 40.7

2

1218-1324

19016 20165 158 13 4.8 2.9 10.2 0.84 0.04 0.57 0.34 0.02 91.7 40.8

3

1337-1431

21314 20606 160 13 6.3 2.9 10.6 0.84 0.04 0.77 0.35 0.02 92.1 54.7

Average 20658 20175 157 14 5.1 2.9 10.4 0.85 0.04 0.63 0.33 0.02 91.8 45.4
Air-Tech Environmental, LLC

Hanson Brick/Columbia Test Report (AT06-0396-HBC)

Test Date: 10/5/2006 - Page 3

2.2 Particulate Sampling Results

Particulate sampling was performed for the determination of filterable PM using

procedures of Method 5. These results are presented in Table 2. The average

concentration of PM was found to be 0.0048 grains per dry standard cubic foot

(gr/dscf), ranging from 0.0025 to 0.006 gr/dscf. These concentrations yield emission

rates that range from 0.43 to 1.03 lb/hr, and average 0.82 lb/hr.

Table 2. Method 5 Results Summary - Plant 4

Run # Time

Concentration

(gr/dscf)

Flow

(dscfm)

Emission

Rate

(#/hr)

Emission Rate

(lb/ton brick)

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

Average 0.0048 20175 0.82 0.037
Air-Tech Environmental, LLC

Hanson Brick/Columbia Test Report (AT06-0396-HBC)

Test Date: 10/5/2006 - Page 4

3.0 SAMPLING AND ANALYTICAL METHODS

The samples were collected from the exhaust of the brick kilns, a natural gas-fired

process operating continuously 24 hours per day, seven days per week. There were no

PM control of emissions from these sources; acid gases were scrubbed in a dry lime

absorber prior to exhaust. A schematic of the process exhaust is contained in Figure 1.

Inlet samples were collected from a circular duct 64 inches in diameter. Two sampling

ports, placed at right angles, provided for access for velocity traverses. A total of 12

points were sampled for velocity measurements. A schematic of this test location

showing sample point location on the “Traverse Point Location Form” has been

appended with the test data. 

DLA outlet sampling was conducted at the exhaust stack from a duct 59.5 inches in

diameter. This sampling location met the requirements of Method 1 allowing a 12-point

particulate matter test to be conducted. A schematic of this location on the “Traverse

Point Location Form” showing point placement has been appended as well. 

Three one hour samples simultaneously were collected from each sampling location. 

Concurrent with the testing readings of DLA pressure drop were made at the facility

monitor, a photohelic differential pressure gauge. These readings were logged

instrumentally at approximately 5 minute intervals by facility monitors.

Sampling was performed according to the procedures of Method 26A at the outlet test

location. These procedures entail isokinetic collection of a particulate sample followed

by collection of acid gases in dilute solutions of sulfuric acid. A schematic of this

sampling train is contained in Figure 2. Note that the caustic impingers used for the

collection of diatomic halogens was not used. 

The flue gas sample was withdrawn through a glass nozzle into a glass probe. 

Particulate matter was filtered through a heated Teflon filter and then entered the

impinger portion of the sampling train. This impinger portion consisted of two impingers

containing 100 ml of 0.1N sulfuric acid each followed by an empty impinger, then a

silica gel containing impinger used for final moisture collection. A type S pitot tube and

type K thermocouple were used to measure velocity pressures and temperatures at

each sampling point. A calibrated dry gas meter was used to measure sample volume. 

A calibrated orifice placed on the meter outlet was used to set sample rate.

Inlet sampling was conducted according to the procedures of Method 26. The nonisokinetic Method 26 sample was collected from three points at the inlet location.
Air-Tech Environmental, LLC

Hanson Brick/Columbia Test Report (AT06-0396-HBC)

Test Date: 10/5/2006 - Page 5

With the exception of not collecting a particulate fraction at the DLA inlet, sample

recovery resulted in the collection of the following sample fractions. 

• Acetone washes, with brushing, of those portions of the sample train

upstream of the filter. 

• The filter.

• The sulfuric acid impinger solutions and water rinses of all exposed glass

surfaces downstream from the filter to the inlet to the silica gel impinger.

• The silica gel.

Acetone washes were dried down in tared beakers for the gravimetric determination of

weight gain. This gain, added to that determined for the tared filters, made up the

particulate total of the sample. The total mass of PM collected was divided by the

sample volume to determine particulate concentration (gr/dscf). This value was

multiplied by flue gas flow rate to determine mass emission rate (lb/hr). Mass

emissions were divided by production rates to determine emissions in terms of brick

production rates (lb/ton). Complete example calculations as well as the analytical and

run data have been appended.

The acid matrix samples were analyzed for fluoride and chloride ions following the ion

chromatography analytical procedures of Method 26A. These analyses yielded liquid

concentrations for the ions of interest (ug/ml). Conversions of ion concentration to acid

concentration were made on a one to one basis. These acid concentrations were then

converted to total mass of the compound of interest collected using the liquid sample

volume. This total mass was then converted to mass rates for each sampling location

in fashion similar to the particulate matter calculations. DLA removal efficiencies were

calculated based on the calculated mass rates of the compounds of interest at the inlet

and outlet. Complete analytical summaries and example calculations have been

appended.

After noting the post test weight gain, the silica gel was discarded. This weight gain

was added to that determined for the rest of the impinger train prior to sample recovery. 

The total weight gain of the impinger train was attributed to flue gas water vapor and

used for flue gas moisture fraction calculations (Method 4). Flue gas fixed gas analysis

was performed on bags collected during each test using the grab procedures of Method

3 using an Orsat combustion analyzer. These data, along with the velocity pressure

and temperature (Method 2) determined each sample point (Method 1) during the

performance of the isokinetic sampling were used to calculate flue gas volumetric flow

rates used in mass rate calculations.
Air-Tech Environmental, LLC

Hanson Brick/Columbia Test Report (AT06-0396-HBC)

Test Date: 10/5/2006 - Page 6

Figure 1. Process Schematic, Hanson Brick
Air-Tech Environmental, LLC

Hanson Brick/Columbia Test Report (AT06-0396-HBC)

Test Date: 10/5/2006 - Page 7

Figure 2. Method 26A Sampling Train
Air-Tech Environmental, LLC

Hanson Brick/Columbia Test Report (AT06-0396-HBC)

Test Date: 10/5/2006 - Page 8

4.0 QUALITY ASSURANCE / QUALITY CONTROL

The Quality Assurance (QA) procedures required by the reference methodologies

employed during the testing were strictly adhered to during the performance of this test

program. Such adherence ensures production of useful and valid data throughout the

course of the project. An analytical audit sample was not provided to Air-Tech for

analysis, therefore the measures made as described below comprise the analytical QA.

Control criteria for these measures are not specified in the method. The QA

procedures described in this section represent an integral part of the overall sampling

and analytical scheme. The acceptance criteria, control limits, and the results of these

measures obtained during this testing and analysis are summarized in Table 4. A brief

discussion of the QA measures is presented below.

QA measures taken to provide some assessment of the quality of sample collection

included measures of sampling rate, and the assessment of the accuracy of metered

gas volumes and the integrity of sampling train. Outlet sampling rates, assessed as %

isokinetics, met method criteria for all test runs. Therefore, any sample bias caused by

non representative collection of differing particle sizes (either particulate matter or water

droplets) was within acceptable limits. The dry gas meters used for sample volume

determination meet method criteria for accuracy. Post-test sample train leak checks

meet the method criteria for all test runs. 

The analytical measures of QA meet the method criteria for acetone purity, an

assessment of the Method 5 analysis. The Method 26A analytical QC relies on

performance of an audit to be provided at the discretion of the SCDHEC. In absence of

such a sample the analytical QA assessment was made based on the measurements

tabulated in Table 4. These data show that the analysis suffered no significant bias

due to the reagents or the sample matrix. All duplicate analysis show a precision of

measurement of exceeding 2% of the reported value for all measurements. The

calibration linearity indicates the results will be accurate regardless of where they fall on

the calibration curve.
Air-Tech Environmental, LLC

Hanson Brick/Columbia Test Report (AT06-0396-HBC)

Test Date: 10/5/2006 - Page 9

Table 4. QA Summary

Criteria Control Limit Result

Sampling

% Isokinetics 100 ± 10% Inlet NA

Outlet 99.2 - 99.5%

Dry Gas Meter Calibration (M26) 1.00 ± 2% Inlet 0.9968

Outlet 1.0046

Post Test Calibration Check (M26A) d y ± 5% Inlet 1.0071

Outlet 0.9674

Sample Train Leak Rate (M26A) <0.02 cfm Inlet 0.00 - 0.00

Outlet 0.00 - 0.00

Analytical

Acetone Blank (M5) # 0.001 wt % 0.0000g/788

H2SO4 Blank (M26A)

W ater Blank (M26A)

results

HF ND

HCl 0.04 :g/ml a

HF ND

HCl ND

Matrix Spike Recovery Not specified HF 104%

Not specified HCl 97.3%

Duplicate Analysis, Inlet ± 5% mean HF 0.1 - 0.3%

± 5% mean HCl 0.1 - 0.4%

Duplicate Analysis, Outlet ± 5% mean HF 0.0 - 0.1 %

± 5% mean HCl 0.0 - 1.1%

Calibration Linearity Not specified HF R = 0.9997 2

Not specified HCl R = 0.9994 2

Value falls between the method detection limit and limit of quantization. a