II-D-121 

Matt, 

Attached please find the responses to the questions on the ICR. 

Thanks, 

Warren 

Responses to Sanford Plant ICR Questions 

IL, 

~ 

6~ 98 

1) The Sanford facility is permitted to use contaminated soil, however, no contaminated soil was 

utilized in 1996. There is no percentage or total amount of contaminated soil identified within 

the current air quality permit. The permit specifies facility wide emission limitations. Please 

keep in mind as noted in the cover letter Cherokee Sanford intends to phase out the use of 

contaminated soiLs in our process over the next few years and does not expect to use 

contaminated soil.s by the time this NESHAP is in effect. 

2) The typical operating range for the sawdust dryers at the Sanford facility would be 

approximately the same as the other plants. The temperature identified in the ICR was 150 

°F and 160 °F for EP-M3-1 and EP-A2-1 & 2 respectively. 

3) The stack test was conducted at the Moncure facility which is substantially identical to the 

Sanford, Lee County & Beltsville facilities. I will mail you a copy of the test report. 
. _ _ .^ _ _ 7 ,_ _ . _ . . ,-_ . _ .r: A .a~a.- 'y~.;S9 - ~ - .. - - - •.. .• :_ ~ 

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CHEROKEE BRICK 

Bricklayer, North Carolina 

January 12, 1995 

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FLUORIDE TESTING RBSULTS 

CHEROKEE BRICK 

Bricklayer, North Carolina 

Prepared for: 

t11an McConnell 

Hunton and Williams 

One Hanover Square 

Favetteville Street Mall 

Raleigh, North Carolina 27602 

Prepared by: 

Hartman Kelly International, Ltd. 

Suite 300B 

1910 Sedwick Road 

Durham, North Carolina 27713 

January 12, 1995 

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Hartman, Kelly International, Ltd. 

January 12,1995 

TABI.E OF CONTENTS 

Eap 

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

2.0 RESULTS ....................................................1 

3.0 SUMMARY OF METHODS AND SAMPLING LOCATIONS . . . . . . . . . . . 2 

FIGURE 

1. EPA Method 26A Sampling Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 

TABLE 

1. Summary of Fluoride Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 

APPENDICES 

APPENDIX A Field Data Sheets 

APPENDIX B Summary Calculation Sheets 

APPENDIX C Laboratory Results 

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Hartman, Kelly International, Ltd. 

January 12,1995 

1 1.0 INTRODUCTION 

~ Hartman, Kelly Intemational, Ltd., (HKi) performed stack testing on December 1, 

1994 for fluoride at Cherokee Brick's Bricklayer, North Carolina facility. This report 

~ presents the results of that testing and the associated background material used. 

The fluoride tests were conducted using U.S. Environmental Protection Agency 

~ (EPA) Method 26A on the East Stack of the cyclone exhaust on the brick kiln. This 

method encompasses EPA Methods 1 through 4 for flows and moisture. The 

impinger solutions were recovered and analyzed at Triangle Laboratories by ion 

~ chromatography. 

~ The kiln was operated at maximum throughput during the entire testing period. The 

average total fluoride emissions were 1.96 pounds per hour (lb/hr). This total was 

calculated by measuring the concentration in the East Stack of the cyclone exhaust 

~ and applying that concentration to the measured flow rate in both the East and West 

Stacks. 

~ Section 2 of this report contains the discussion of results and a summary of results. 

Section 3 is a description of the sampling and analytical methods. The Field data and 

~ laboratory data are contained in the appendices. 

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Hartman, Kelly International, Ltd. 

January 12,1995 

2.0 RESULTS 

~ Fluoride emission testing conducted on December 1, 1994, is summarized in Table 1. 

The emission rate averaged 1.961b/hr with a range of 1.78 to 2.061b/hr. Each nin 

~ total was obtained from summing the results of both the East and West Stacks. The 

East Stack was measured simultaneously for flow and concentration. The West Stack 

was measured for flow before or after each test run at the East Stack. The analvtical 

~ results for the East Stack were applied to the West Stack flow rate to achieve the 

mass emission rate for the West Stack. 

~ The samples were withdrawn isokinetically over a 1-hour period. The isokinetics 

ranged from 98 to 103% during the test period. There were three 1-hour tests 

~ conducted on the East Stack, interspersed with three flow rate measurements on the 

West Stack. As can be seen from Table 1, the flow rates on the West Stack are 

higher than the East Stack by approximately 25%. The reason for the difference is 

~ not known since the fans are the same size. There was a loss of power in the kiln 

between Runs 1 and 2. Testing was not performed during the outage, but was 

~ resumed when power was restored. 

Table 1. Summary of Fluoride Emissions 

Run 1 

East' 

Run 1 

Westb 

Run 2 

East 

Run 2 

West 

Run 3 

East 

Run 3 

West 

Stack Velocity, fpm 3240 4325 3465 4280 3434 4303 

Volumetric Flow Rate, dscfm 11780 14814 11776 14505 11853 14834 

Fluoride Concentration, ppm 26.2 26.2 26.5 26.5 22.6 22.6 

Fluoride Emissions, Ib/hr 0.91 1.14 0.92 1.14 0.79 0.99 

Total, lb/hr 2.05 2.06 1.78 

Average, lb/hr 1.96 

'This stack was sampled with the fluoride sampling train. 

~ "This stack was measured for flow and the concentration of the East Stack was applied to the flow rate 

to yield the emission number. 

~ There were no known problems encountered during this test series. The sampling 

conformed to EPA specifications and the analyses were within the analytical range 

specified in the method. 

~ 

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January 12,1995 

~ 3.0 SUMMARY OF METHODS AND SAMPLING LOCATIONS 

~ The fluoride emissions were determined according to EPA Method 26A at the outlet 

for the wood dust dryer cyclone. Both stacks were sampled after the fans and prior to 

~ exhaust into the air. Both stacks had the same diameter (29" ID) and both sampling 

locations were approximately 9 feet above the fan exhaust and approximately 40 feet 

tothe air discharge. Twent.y-four sampling points were used in order to maximize 

~ accuracy of the flow readings. 

~ 

The sample was withdrawn isokinetically through a calibrated nozzle into the 

impingers for collection and was then determined volumetrically with a calibrated dry 

gas meter. Figure 1 presents a schematic drawing of the sampling train. After one 

~ hour of sampling, the sample was recovered in the field using procedures in 

Method 26A. The collected sample was transported to Triangle Laboratories in 

Research Triangle Park, North Carolina for analysis by ion chromatography. 

~ The analysis was pe fo r rmed b calibratin the chromato a h with standards and y g gr p 

~ blanks prior to and after the sample injections. The results are contained in 

Appendix C. All of the samples fell in the range of calibrations. As a quality control 

check, blanks were run as well as duplicate injections of the samples. 

~ Flows were determined by a Type S pitot tube which was measured in accordance 

with EPA Method 2. The molecular weight was determined by obtaining oxygen, 

~ carbon dioxide, and nitrogen by balance with an ORSAT-type apparatus. Moisture 

was determined gravimetrically by measuring the moisture trapped in the dryers and 

~ silica gel during the testing. 

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January 12,1995 

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~ FIELD DATA SHEETS 

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SUMMARY CALCULATION SHEETS 

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Facility: CHEROKEE 

~ Date: 12/01 /94 

Location: EAST STACK 

Run Number: 1 

Sample Type: FLTotal Sampling Time (min) 60.0 

Corrected Barometric Pressure (in Hg) 30.09 

Absolute Stack Pressure (in H20) 30.07 

Stack Static Pressure (in H20) -0.30 

Average Stack Temperature (°F) 180.38 

Stack Area (sq in) 660.52 

Actual Meter Votume (cu ft) 29.507 

Average Meter Pressure (in H20) 0.92 

Average Meter Temperature (°F) 68.65 

Moisture Collected (g) 70.00 

Carbon Dioxide Concentration (%V) 3.5 

Oxygen Concentration (%V) 16.5 

Nitrogen Concentration (%V) 80.0 

Dry Gas Meter Factor 1.0050 

Nozzle Diameter (in) 0.190 

Pitot Constant 0.84 

Average Sampling Rate (dscfm) 0.497 

Standard Metered Volume (dscf) 29.841 

Standard Metered Volume (dscm) 0.845 

Stack Moisture (%V) 9.96 

Mole Fraction Dry Stack Gas 0.900 

Dry Molecular Weight 29.22 

Wet Molecular Weight 28.10 

Stack Gas Velocity (fpm) 3442.37 

Stack Gas Velocity (mpm) 1049.23 

Volumetric Flow Rate (acfm) 15789.96 

Volumetric Flow Rate (acmm) 447.17 

Volumetric Flow Rate (dscfm) 11780.07 

Volumetric Flow Rate (dscmm) 333.61 

Percent Isokinetic 98.36 

Percent Excess Air 355.91 

Floride Concentration (g/dscm) 0.02 

Floride Emissions (kg/hr) 0.41 

Floride Concentration (ppmv) 26.20 

Floride Emissions (Ib/hr) 0.91 

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Facility: CHEROKEE 

~ Date: 12/01 /94 

Location: EAST STACK 

Run Number: 2 

, Sample Type: FL- 

_ Total Sampling Time (min) 72.0 

~ Corrected Barometric Pressure (in Hg) 30.09 

Absolute Stack Pressure (in H20) 30.07 

~ Stack Static Pressure (in H20) -0.27 

Average Stack Temperature (°F) 180.21 

Stack Area (sq in) 660.52 M Actual Meter Volume (cu ft) 37.427 

Average Meter Pressure (in H20) 0.92 

Average Meter Temperature (°F) 69.94 

Moisture Collected (g) 95.00 

~ Carbon Dioxide Concentration (%V) 3.0 

Oxygen Concentration (%V) 16.5 

~ Nitrogen Concentration (%V) 80.5 

Dry Gas Meter Factor 1.0050 

Nozzle Diameter (in) 0.190 

~ Pitot Constant 0.84 

Average Sampling Rate (dscfm) 0.525 

Standard Metered Volume (dscfl 37.768 

~ Standard Metered Volume (dscm) 1.070 

Stack Moisture (%V) 10.60 

Mole Fraction Dry Stack Gas 0.894 

~ Dry Molecular Weight 29.14 

Wet Molecular Weight 27.96 

Stack Gas Velocity (fpm) 3464.85 

~ Stack Gas Velocity (mpm) 1056.09 

Volumetric Flow Rate (acfm) 15893.06 

Volumetric Flow Rate (acmm) 450.09 

~ Volumetric Flow Rate (dscfm) 11776.16 

Volumetric Flow Rate (dscmm) 333.50 

Percent Isokinetic 103.77 

~ Percent Excess Air 346.05 

Floride Concentration (g/dscm) 0.02 

~ Floride Emissions (kg/hr) 0.42 

Floride Concentration (ppmv) 26.50 

Floride Emissions (Ib/hr) 0.92 

0 
Facility: 

Date: 

Location: 

Run Number: 

Sample Type: 

CHEROKEE 

12/01 /94 

EAST STACK 

3 

FLTotai Sampting Time (min) 72,0 

Corrected Barometric Pressure (in Hg) 30.09 

Absolute Stack Pressure (in H20) 30.06 

- Stack Static Pressure (in H20) . -0.45 

Average Stack Temperature (°F) 180.79 

Stack Area (sq in) 660.52 

Actual Meter Volume (cu ft) 37.228 

Average Meter Pressure (in H20) 0.92 

Average Meter Temperature (°F) 68.21 

Moisture Collected (g) 80.00 

Carbon Dioxide Concentration (%V) 3.0 

i Oxygen Concentration (%V) 16.5 

~ Nitrogen Concentration (%V) 80.5 

Dry Gas Meter Factor 1.0050 

Nozzle Diameter (in) 0.190 

~ Pitot Constant 0.84 

Average Sampling Rate (dscfm) 0.524 

Standard Metered Volume (dscfl 37.709 

~ Standard Metered Volume (dscm) 1.068 

Stack Moisture (%V) 9.09 

Mole Fraction Dry Stack Gas 0.909 

~ Dry Molecular Weight 29.14 

Wet Molecular Weight 28.13 

Stack Gas Velocity (fpm) 3434.49 

~ Stack Gas Velocity (mpm) 1046.83 

Volumetric Flow Rate (acfm) 15753.83 

Volumetric Flow Rate (acmm) 446.15 

~ Volumetric Flow Rate (dscfm) 11853.98 

Volumetric Flow Rate (dscmm) 335.70 

~ Percent Isokinetic 

Percent Excess Air 

102.93 

346.05 

Floride Concentration (g/dscm) 0.02 

~ Floride Emissions (kg/hr) 0.36 

Floride Concentration (ppmv) 22.60 

Floride Emissions (Ib/hr) 0.79 

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Facility: CHEROKEE 

Date: 12/01 /94 

Location: WEST STACK 

Run Number: 1 

Sample Type: FLTotal Sampling Time (min) 

~ Corrected Barometric Pressure (in Hg) 30.09 

Absolute Stack Pressure (in H20) 30.07 

Stack Static Pressure (in H20) -0-30 

~ Average Stack Temperature (°F) 179.79 

Stack Area (sq in) 660.52 

Actual Meter Volume (cu ft) 29.507 

~ Average Meter Pressure (in H20) 1.15 

Average Meter Temperature (°F) 68.65 

~ Moisture Collected (g) 70.00 

Carbon Dioxide Concentration (%V) 3.5 

Oxygen Concentration (%V) 16.5 

~ Nitrogen Concentration (%V) 80.0 

Dry Gas Meter Factor 1.0050 

Nozzle Diameter (in) 

~ Pitot Constant 0.84 

Average Sampling Rate (dscfm) 0.497 

Standard Metered Volume (dscf) 29.841 

~ 

Standard Metered Volume (dscm) 0.845 

. Stack Moisture (%V) 9.96 

Mole Fraction Dry Stack Gas 0.900 

~ Dry Molecular Weight 29.22 

Wet Molecular Weight 28.10 

Stack Gas Velocity (fpm) 4325.03 

~ Stack Gas Velocity (mpm) 1318.27 

Volumetric Flow Rate (acfm) 19838.66 

Volumetric Flow Rate (acmm) 561.83 

~ Volumetric Flow Rate (dscfm) 14814.09 

Volumetric Flow Rate (dscmm) 419.54 

Percent Isokinetic 

~ Percent Excess Air 355.91 

Floride Concentration (g/dscm) 0.02 

Floride Emissions (kg/hr) 0.52 

~ Floride Concentration (ppmv) 26.20 

~ 

Floride Emissions (Ib/hr) 

-------------- ---- -------------- ------------ -------- --------- --------- --------- --------- 

1.14 

--------- ---------- 

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Facility: 

Date: 

Location: 

Run Number: 

Sample Type: 

CHEROKEE 

12/01 /94 

WEST STACK 

2 

FLTotal Sampling Time (min) 

~ Corrected Barometric Pressure (in Hg) 30.09 

Absolute Stack Pressure (in H20) 30.07 

Stack Static Pressure (in H20) _ -0.27 

~ Average Stack Temperature (°F) 182.13 

Stack Area (sq in) 660.52 

~ Actual Meter Volume (cu ft) 37.427 

Average Meter Pressure (in H20) 1.14 

Average Meter Temperature (°F) 69.94 

Moisture Collected (g) 95.00 

~ Carbon Dioxide Concentration (%V) 3.0 

Oxygen Concentration (%V) 16.5 

~ Nitrogen Concentration (%V) 80.5 

Dry Gas Meter Factor 1.0050 

Nozzle Diameter (in) 

~ Pitot Constant 0.84 

Average Sampling Rate (dscfm) 0.525 

Standard Metered Volume (dscfl 37.768 

~ Standard Metered Volume (dscm) 1.070 

Stack Moisture (%V) 10.60 

Mole Fraction Dry Stack Gas 0.894 

' Dry Molecular Weight 29.14 

Wet Molecular Weight 27.96 

Stack Gas Velocity (fpm) 

~ Stack Gas Velocity (mpm) 

4280.54 

1304.71 

Volumetric Flow Rate (acfm) 19634.60 

Volumetric Flow Rate (acmm) 556.05 

~ Volumetric Flow Rate (dscfm) 14505.06 

Volumetric Flow Rate (dscmm) 410.78 

Percent Isokinetic 

~ Percent Excess Air 346.05 

Floride Concentration (g/dscm) 0.02 

' Floride Emissions (kg/hr) 0.52 

Floride Concentration (ppmv) 26.50 

Floride Emissions (Ib/hr) 1.14 

1 
Facility: CHEROKEE 

Date: 12/01 /94 

Location: WEST STACK 

Run Number: 3 

Sample Type: FLTotal Sampling Time (min) 

Corrected Barometric Pressure (in Hg) 30.09 

Absolute Stack Pressure (in H20) 30.06 

Stack Static Pressure (in H20) . -0.45 

Average Stack Temperature (°F) 181.54 

Stack Area (sq in) 660.52 

Actual Meter Volume (cu ft) 37.228 

Average Meter Pressure (in H20) 1.15 

Average Meter Temperature (°F) 68.21 

Moisture Collected (g) - 80.00 

Carbon Dioxide Concentration (%V) 3.0 

Oxygen Concentration (%V) 16.5 

Nitro,gen Concentration (%V) 80.5 

Dry Gas Meter Factor 1.0050 

Nozzle Diameter (in) 

Pitot Constant 0.84 

Average Sampling Rate (dscfm) 0.524 

Standard Metered Volume (dscfl 37.709 

Standard Metered Volume (dscm) 1.068 

Stack Moisture (%V) 9.09 

Mole Fraction Dry Stack Gas 0.909 

Dry Molecular Weight 29.14 

Wet Molecular Weight 28.13 

Stack Gas Velocity (fpm) 4303.03 

Stack Gas Velocity (mpm) 1311.56 

Volumetric Flow Rate (acfm) 19737.74 

Volumetric Flow Rate (acmm) 558.97 

Volumetric Flow Rate (dscfm) 14834.31 

Volumetric Flow Rate (dscmm) 420.11 

Percent Isokinetic 

Percent Excess Air 346.05 

Floride Concentration (g/dscm) 0.02 

Floride Emissions (kg/hr) 0.45 

Floride Concentration (ppmv) 22.60 

Floride Emissions (Ib/hr) 0.99 

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APPENDIX C 

A LABORATORY RESULTS 

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Data Reprocessed On 12/06/1994 09:00:42 

Sample Name: 1 Date: 12/05/1994 20:11 44 

Data File : C:\DX\DATA\30704F\92148011.D17 

Method : C:\DX\METHOD\7ANION.met 

ACI Address: 1 System: 1 Inject#: 17 Detector:PED-Cond. 

Analyst : Column: 

Calibration Volume Dilution Points Rate Start Stop Area Reject 

-------------------------------------------------------------------- 

External 1 1 3600 5Hz 0.00 6.93 1000 

********************** Component Report: A11 Components 

Pk. Ret Component Concentration Height Area Bl. %Delta 

Num Time Name Code 

----------------------------------------------------------------------------- 

1 1.47 FLUORIDE 0.000 31471721 417396257 1 0.00 

0 0.00 CHLORIDE 0.000 0 0 0 0.00 

0 0.00 BROMIDE 0.000 0 0 0 0.00 

0 0.00 NITRATE 0.000 0 0 0 0.00 

0 0.00 SULFATE 0.000 0 0 0 0.00 

------------------------------------ 

Totals 0.000 31471721 417396257 

File: 92148011.D17 Samp/e: 1 

0 1 2 3 4 5 6 

Minutes 

PW 

I --1 11:z- 
1 40 

1 30 

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20 

1 10 

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Data Repr.ocessed On 12/06/1994 09:03:10 

Sample Name: 1 N rDate: 12/05/1994 20:25:29 w Data File : C:\DX\DATA\30704F\92148011.D18 

Method : C:\DX\METHOD\7ANION.met 

ACI Address: 1 System: 1 Inject#: 18 Detector:PED-Cond. 

Analyst . Column: 

Calibration Volume Dilution Points Rate Start Stop Area Reject 

-------------------------------------------------------------------- 

External 1 1 3600 5Hz 0.00 6.57 1000 

********************** Component Report: A11 Components 

Pk. Ret Component Concentration Height Area B1. %Delta 

Num Time Name Code 

----------------------------------------------------------------------------- 

1 1.47 FLUORIDE 0.000 33898814 429597167 1 0.00 

0 0.00 CHLORIDE 0.000 0 0 0 0.00 

0 0.00 BROMIDE 0.000 0 0 0 0.00 

0 0.00 NITRATE 0.000 0 0 0 0.00 

0 0.00 SULFATE 0.000 0 0 0 0.00 

------------------------------------ 

Totals 0.000 33898814 429597167 

File: 92148011.D18 Samp/e: 1 

23 

Minutes 

1 -0r_ 
0 1 2 3 4 5 6 

Minutes 

1 w 

I 30 

I uS 20 

1 10 

1 ° 

I 

I 

Data Reprocessed On 12/06/1994 09:04:26 

~ Sample Name: 2 Date: 12/05/1994 20:39:15 

Data File : C:\DX\DATA\30704F\92148021.D19 

Method : C:\DX\METHOD\7ANION.met 

ACI Address: 1 System: 1 Inject#: 19 Detector:PED-Cond. 

~ Analyst =-----

~ --~ 

Column~

-= 

~

Calibration Volume Dilution Points Rate Start Stop Area Reject 

-------------------------------------------------------------------- 

External 1 1 3600 5Hz 0.00 6.80 1000 

********************** Component Report: A11 Components ********************** 

Pk. Ret Component Concentration Height Area B1. %Delta 

~

Num Time Name Code 

1 1.47 FLUORIDE 

, ----------------------------------------------------------------------------- 

0.000 30963917 393850585 1 0.00 

0 0.00 CHLORIDE 0.000 0 0 0 0.00 

0 

~ 

0.00 BROMIDE 0.000 0 0 0 0.00 

0 0.00 NITRATE 0.000 0 0 0 0.00 

0 0.00 SULFATE 0.000 

-------------- ----------- 

0 0 

----------- 

0 0:00 

~ 

Totals 0.000 30963917 393850585 

I File: 92948021.D19 Samp/e: 2 

24 

~) 1-7 
1 40 

1 30 

I us 20 

1 10 

1 ° 

I Minutes 

Data Reprocessed On 12/06/1994 09:06:27 

~ Sample Name: 2 Date: 12/05/1994 20:53:01 

Data File : C:\DX\DATA\30704F\92148021.D20 

Method : C:\DX\METHOD\7ANION.met 

ACI Address: 1 System: 1 Inject#: 20 Detector:PED-Cond. 

~ =-

Analyst

==--------- ------c

olwnn

_________________ 

~

Calibration Volume Dilution Points Rate -Start---Stop Area Reject 

------------------------------------------- ------------- 

External 1 1 3600 5Hz 0.00 6.39 1000 

Component Report: A11 Components ********************** 

Pk. Ret Component Concentration Height Area B1. %Delta 

~

Num Time Name 

----------------------------------------------------------------------------- 

Code 

1 1.47 FLUORIDE 0.000 31256746 405088472 1 0.00 

~ 0 

0 

0.00 

0.00 

CHLORIDE 

BROMIDE 

0.000 

0.000 

0 

0 

0 

0 

0 

0 

0.00 

0.00 

0 0.00 NITRATE 0.000 0 0 0 0.00 

0 0.00 SULFATE 0.000 0 0 0 0.00 

~ -------------- ----------- 

Totals 0.000 

----------- 

31256746 405088472 

~ File: 92148021.D20 Samp/e: 2 

I 

I 

25 

-, a 
0 1 - 2 3 4 5 6 

I uS 20 

40 

~ 

' 10 

i ° 

Data.Reprocessed On 12/06/1994 09:07:48 

Sample Name: 3 Date: 12/05/1994 21:06:46 

Data File : C:\DX\DATA\30704F\92148031.D21 

Method : C:\DX\METHOD\7ANION.met 

ACI Address: 1 System: 1 Inject#: 21 Detector:PED-Cond. 

Analyst . Column: 

I

Calibration Volume Dilution Points Rate Start Stop Area Reject 

External 1 1 3600 5Hz 0.00 6.57 1000 

( ********************** Component Report: A11 Components *********************** 

Pk. Ret Component Concentration Height Area B1. $Delta 

I

Num Time Name -Code 

1 1.47 FLUORIDE 

----------------------------------------------------------------- 

0.000 28381722 370167550 1 

--------- 

0.00 

0 0.00 CHLORIDE 0.000 0 0 0 0.00 

0 0.00 

~ 

BROMIDE 0.000 0 0 0 0.00 

0 0.00 NITRATE 0.000 0 0 0 0.00 

0 0.00 SULFATE 0.000 

-------------- 

0 

----------- 

0 0 0:00 

~ 

Totals 0.000 28381722 

----------- 

370167550 

I File: 92148031.D21 Sample: 3 

Minutes 

1 26 e1% r-n 
1 w 

1 30 

I uS 20 

~ 10 

~ 0 

~ Data Reprocessed On 12/06/1994 09:11:41 

Sample Name: 3 Date: 12/05/1994 21:20:31 

~ Data File : C:\DX\DATA\30704F\92148031.D22 

Method : C:\DX\METHOD\7ANION.met 

ACI Address: 1 System: 1 Inject#: 22 Detector:PED-Cond. 

~ Analyst : Column: 

'

Calibration 

-------------------------------------------------------------------- 

Volume Dilution Points Rate Start Stop Area Reject 

External 1 1 3600 5Hz 0.00 6.80 1000 

Component Report: A11 Components 

Pk. Ret Component Concentration Height Area B1. %Delta 

~

Num Time Name 

----------------------------------------------------------------------------- 

Code 

1 1.47 FLUORIDE 0.000 28228969 367316049 1 0.00 

~ 0 0.00 CHLORIDE 0.000 0 0 0 0.00 

0 0.00 BROMIDE 0.000 0 0 0 0.00 

0 0.00 NITRATE 0.000 0 0 0 0.00 

0 0.00 SULFATE 0.000 0 0 0 0.00 

~ --------- ---------------------- --- -- 

Totals 0.000 28228969 367316049 

I File: 92948031.D22 Sample: 3 

~ 

~ 

0 1 2 3 4 5 6 

Minutes 

I 

I 

0 27 
~ _r ~ 

w ~ 0 

v 

A 

T r 

C ~ O 

~ 

m v 

~ 

~ 

i 

1 

i 

I 

~ -~ , 
180 

160 

140 

120 

100 

us 

80 

60 

40 

20 

0 

-20 

0 2 4 6 8 10 12 

Data Reprocessed On 12/06/1994 10:40:11 

Sample Name: STD 100.0 PPM Date: 12/05/1994 19:02:52 

Data File : C:\DX\DATA\30704F\STD10001.D12 

Method : C:\DX\METHOD\7ANION.met 

ACI Address: 1 System: 1 Inject#: 12 Detector:PED-Cond. 

Analyst . Column: 

3libration Volume Dilution Points Rate Start Stop Area Reject 

------------------------------------------------------------------- 

xternal 1 1 3600 5Hz 0.00 12.00 1000 

********************* Component Report: A11 Components *********************** 

Pk. Ret Component Concentration Height Area B1. %Delta 

Num Time Name 

---------------------------------------------------------------------------- 

Code 

1 1.43 FLUORIDE 0.000 102554617 973235053 1 0.00 

2 2.33 CHLORIDE 0.000 119602937 978557491 1-0.71 

0 0.00 BROMIDE 0.000 0 0 0 0.00 

0 0.00 NITRATE 0.000 0 0 0 0.00 

3.10.30 SULFATE 0.000 22479602 

------------------------------------ 

559206713 1-0.29 

Totals 0.000 244637156 2510999257 

File: STD10001.D12 Sample: STD 100.0 PPM 

Minutes 
90 

80 

70 

60 

50 

uS 40 

30 

20 

10 

0 

0 2 4 6 8 10 12 

Data Reprocessed On 12/06/1994 10:25:39 

Sample Name: STD 30.0 PPM Date: 12/05/1994 18:35 18 ' 

Data File : C:\DX\DATA\30704F\STD03001.D10 

Method : C:\DX\METHOD\7ANION.met 

ACI Address: 1 System: 1 Inject$: 10 Detector:PED-Cond. 

Analyst . Column: 

Calibration Volume Dilution Points Rate Start Stop Area Reject 

External 

-------------------------------------------------------------------- 

1 1 3600 5Hz 0.00 12.00 1000 

********************** Component Report: A11 Components *********************** 

Pk. Ret Component Concentration Height Area B1. %Delta 

Num Time Name 

----------------------------------------------------------------------------- 

Code 

1 1.42 FLUORIDE 0.000 36622684 266239467 1 0.00 

2 2.27 CHLORIDE 0.000 43297647 266513565 1-3.55 

0 0.00 BROMIDE 0.000 0 0 0 0.00 

0 0.00 NITRATE 0.000 0 0 0 0.00 

3 10.47 SULFATE 0.000 

------------------------------------ 

6277965 154854816 1 1:32 

Totals 0.000 86198295 687607848 

File: STD03001.D1 0 Sample: STD 30.0 PPM 

Minutes 

8 
Data Reprocessed On 12/06/1994 10:07:31 

Sample Name: STD 10.0 PPM Date: 12/05/1994 18:07:45 

Data File : C:\DX\DATA\30704F\STDOl001.D08 

Method : C:\DX\METHOD\7ANION.met 

ACI Address: 1 System: 1 Inject#: 8 Detector:PED-Cond. 

Analyst . Column: 

Calibration Volume Dilution Points Rate Start Stop Area Reject 

-------------------------------------------------------------------- 

External 1 1 3600 5Hz 0.00 12.00 1000 

********************** Component Report: A11 Components *********************** 

Pk. Ret Component Concentration Height Area B1. %Delta 

Num Time Name Code 

1 1.40 FLUORIDE 

----------------------------------------------------------------------------- 

0.000 9668466 79630351 1 0.00 

2 2.25 CHLORIDE 0.000 13756779 75218587 1-4.26 

0 0.00 BROMIDE 0.000 0 0 0 0.00 

0 0.00 NITRATE 0.000 0 0 0 0.00 

3 10.53 SULFATE 0.000 2134718 52907034 1 1:97 

Totals 0.000 

------------------------------------ 

25559962 207755973 

File: STD01001.D08 Sample: STD 10.0 PPM 

CHLORIDE / 2.25 

2 4 6 8 10 12 

Minutes 

uS 

18 

16 

14 

12 

10' 

8 

6 

4 

2 

0 

.2 

0 
Data Reprocessed On 12/06/1994 09:55:06 

Sample Name: STD 3.0 PPM Date: 12/05/1994 17:40:13 

Data File : C:\DX\DATA\30704F\STD00301.D06 

Method : C:\DX\METHOD\7ANION.met 

ACI Address: 1 System: 1 Inject#: 6 Detector:PED-Cond. 

Analyst : Column: 

Calibration 

~ 

Volume ______________________________ 

Dilution-Points-Rate--Start---Stop Area ______________ 

Reject 

External 1 1 3600 5Hz 0.00 12.00 1000 

I ********************** Component Report: A11 Components *********************** 

Pk. Ret Component Concentration Height Area B1. %Delta 

~

Num Time Name 

----------------------------------------------------------------------------- 

Code 

1 1.40 FLUORIDE 0.000 2188236 20472716 1 0.00 

' 2 2.25 CHLORIDE 0.000 3668883 20965534 1-4.26 

0 0.00 BROMIDE 0.000 0 0 0 0.00 

0 0.00 NITRATE 0.000 0 0 0 0.00 

3 10.58 SULFATE 0.000 920008 24519245 1 2:45 

Totals 0.000 6777127 65957494 

File: STD00301.D06 Samp/e: STD 3.0 PPM 

I 

I 

9.0 

8.0 

7.0 

6.0 

5.0 CHLORIDE / 2.25 

uS 4.0 

1 

3.0 FLUORIDE / 1. 0 

2.0 I ~ 

1.0 

0.0 

-1.0 

0 2 4 6 

Minutes 

SULFATE / 10.58 

~ ~ 

8 10 12 

■ 10 :?< 
Data Reprocessed On 12/06/1994 09:14:13 __---____-----_=---____________________ ~ Sample Name: STD 1.0 PPM Date: 12/05/1994 17:12:42 

Data File : C:\DX\DATA\30704F\STDO0101.D04 

Method : C:\DX\METHOD\7ANION.met 

ACI Address: 1 System: 1 Inject#: 4 Detector:PED-Cond. 

~ --Analyst ==--------_ —---==Column _________________---____________=____—_ 

~ 

Calibration Volume D1lution Points Rate Start Stop Area Reject 

-------------------------------------------------------------------- 

External 1 1 3600 5Hz 0.00 12.00 1000 

I ********************** Component Report: A11 Components 

Pk. Ret Component Concentration Height Area B1. %Delta 

~ Num Time 

---- ------- 

Name 

----- ------------------------------------------------------------- 

Code 

1 1.42 FLUORIDE 0.000 597491 4826444 1 0.00 

~ 2 2.25 CHLORIDE 0.000 1213151 6773985 1-4.26 

0 0.00 BROMIDE 0.000 0 0 0 0.00 

0 0.00 NITRATE 0.000 0 0 0 0.00 

_ 3 10.58 SULFATE 0.000 656186 17791547 1 2:45 

Totals 0.000 2466828 29391975 

I File: STD00101.D04 Sample: STD 1.0 PPM 

a 

3.0 

' 

2.0 

~ uS 

1.0 

~ 

0.0 

~ 

-1.0 

CHLORIDE / 2.25 

1 

FLUORIDE / 1 

1 

SULFATE / 10.58 

1 

0 2 4 6 8 10 12 

Minutes 

11 ?/ - 
File: STD1000l.D42 Sample: STD 100.0 PPM 

180 

160 

140 CHLORIDE / 2.33 

120 

100 

80 

60 

40 

20 

0 

-20 

0 2 4 6 8 10 12 

Minutes 

Data Reprocessed On 12/06/1994 10:43:36 

I Sampie Name: STD 100.0 PPM Date: 12/06/1994 01:55:52 

Data File : C:\DX\DATA\30704F\STD10001.D42 

Method : C:\DX\METHOD\7ANION.met 

ACI Address: 1 System: 1 Inject#: 42 Detector:PED-Cond. 

I wAnalyst_

~ _Column:_

= 

~ Calibration Volume Dilution Points Rate Start Stop Area Reject 

External 1 1- 3600 5Hz 0.00 12.00 1000 

Component Report: A11 Components 

Pk. Ret Component Concentration Height Area B1. %Delta 

I

Num Time Name Code 

1 1.43 FLUORIDE 

----------------------------------------------------------------------------- 

0.000 106306214 985906646 1 0.00 

2 2.33 CHLORIDE 0.000 121908984 1001519667 1-0.71 

0 

~ 

0.00 BROMIDE 0.000 0 0 0 0.00 

0 0.00 NITRATE 0.000 0 0 0 0.00 

3 10.27 SULFATE 0.000 

-------------- ----------- 

22668878 567476070 1-0.61 

' ----------- 

Totals 0.000 250884076 2554902384 

I 

I 

I us 

I 

I 

I 

I 

19 2 -T 
~ 

Minutes 

Data_Reprocessed On 12/06/1994 10:36:37 

~ Sample Name: STD 30.0 PPM Date: 12/06/1994 01:28:17 

Data File : C:\DX\DATA\30704F\STD03001.D40 

Method : C.\DX\METHOD\7ANION.met 

ACI Address: 1 System: 1 Inject#: 40 Detector•PED-Cond. 

~ _Analyst~Y: _Column: 

~ Calibration Volume Dilution Points Rate Start Sto P Area Reject 

External 1 1 3600 5Hz 0.00 12.00 1000 

********************** Component Report: All Components *********************** 

Pk. Ret Component Concentration Height Area B1. $Delta 

~

Num Time Name Code 

1 1.42 FLUORIDE 

----------------------------------------------------------------------------- 

0.000 38259577 272864010 1 0.00 

~ 2 2.27 CHLORIDE 0.000 44091172 271195040 1-3.55 

0 0.00 BROMIDE 0.000 0 0 0 0.00 

0 0.00 NITRATE 0.000 0 0 0 0.00 

3 10.43 SULFATE 0.000 6191573 148379265 1 1:00 

~ ------------------------------------ 

Totals 0.000 88542322 692438315 

I File: STD03001.D40 Sample: STD 30.0 PPM 

~ 90 

80 

~ 70 

60 

~ 50 

uS 40 

~ 30 

20 

~ 10 

0 

1 13 ?d 
~ 

~ 

~ 

~ 

~ 

~ 

~ 

~ 

us 

File: STD01009.D38 Samp/e: STD 10.0 PPM 

18 

16 

14 

12 

10 

8 

6 

4 

2 

0 

-2 

0 2 4 6 8 10 12 

Minutes 

Data'Reprocessed On 12/06/1994 10:21:29 

~ Sample Name: STD 10.0 PPM Date: 12/06/1994 01:00:44 

Data File : C:\DX\DATA\30704F\STDO1001.D38 

Method : C:\DX\METHOD\7ANION.met 

ACI Address: 1 System: 1 Inject#: 38 Detector:PED-Cond. I Analyst----=___-- 

Column

_=--~~ 

f

Calibration Volume Dilution Points Rate Start Stop Area Reject 

External 1 1 

-------------------------------------------------------------------- 

3600 5Hz 0.00 12.00 1000 

Component Report: A11 Components 

Pk. 

~ Num 

Ret 

Time 

---- ------- 

Component 

Name 

----- ------------------------------------------------------ 

Concentration Height Area H1. 

Code 

%Delta 

------- 

1 1.40 FLUORIDE 0.000 10117145 80090068 1 0.00 

' 2 2.25 CHLORIDE 0.000 13814148 76490029 1-4.26 

0 0.00 BROMIDE 0.000 0 0 0 0.00 

0 0.00 NITRATE 0.000 0 0 0 0.00 

_ 3 10.52 SULFATE 0.000 2030733 51277234 1 1:81 

Totals 0.000 25962026 207857331 

m 
Data Reprocessed On 12/06/1994 10:56:15 

Sample Name: STD 3.0 PPM Date: 12/06/1994 00:33:13 ~ 

Data File : C:\DX\DATA\30704F\STD00301.D36 

Method : C:\DX\METHOD\7ANION.met 

ACI Address: 1 System: 1 Inject#: 36 Detector:PED-Cond. 

Analyst : Column: 

Calibration Volume Dilution Points Rate Start Stop Area Reject 

-------------------------------------------------------------------- 

External 1 1 3600 5Hz 0.00. 12.00 1000 

********************** Component Report: A11 Components ********************** 

Pk. Ret Component Concentration Height Area B1. %Delta 

Num Time Name 

----------------------------------------------------------------------------- 

Code 

1 1.40 FLUORIDE 0.000 2380345 21472171 1 0.00 

2 2.23 CHLORIDE 0.000 3411424 20962105 1-4.96 

0 0.00 BROMIDE 0.000 0 0 0 0.00 

0 0.00 NITRATE 0.000 0 0 0 0.00 

3 10.55 SULFATE 0.000 730323 

------------------------------------ 

19228545 1 2:13 

Totals 0.000 6522093 61662821 

File: STD00301.D36 Samp/e: STD 3.0 PPM 

4.0 

3.0 

2.0 

uS 1.0 

0.0 

-1.0 

-2.0 

0 2 4 6 8 10 12 

Minutes 

1 S J 1 ._ 
Data Reprocessed On 12/06/1994 09:51:43 

Sample Name: STD 1.0 PPM Date: 12/06/1994 00:05:43 

Data File : C:\DX\DATA\30704F\STDO0101.D34 

Method : C:\DX\METHOD\7ANION.met 

ACI Address: 1 System: 1 Injecti: 34 Detector:PED-Cond. 

Analyst : Column: 

Calibration Volume Dilution Points Rate Start Stop Area Reject 

External 

-------------------------------------------------------------------- 

1 1 3600 5Hz 0.00 12.00 1000 

********************** Component Report: A11 Components *********************** 

Pk. Ret Component Concentration Height Area B1. $Delta 

Num Time Name 

----------------------------------------------------------------------------- 

Code 

1 1.40 FLUORIDE 0.000 631325 4970085 1 0.00 

2 2.23 CHLORIDE 0.000 1078446 6791602 1-4.96 

0 0.00 BROMIDE 0.000 0 0 0 0.00 

0 0.00 NITRATE 0.000 0 0 0 0.00 

3 10.57 SULFATE 0.000 391123 

------------------------------------ 

10395843 1 2.29 

Totals 0.000 2100894 22157530 

F11e: STD00101.D34 Samp/e: STD 1.0 PPM 

4.0 

3.0 

2.0 

uS 

1.0 

0.0 

-1.0 

0 2 4 6 8 10 12 

Minutes 

16 

Z// 
Data.Reprocessed On 12/06/1994 11:13:42 

Sample Name: H2OBLANK Date: 12/05/1994 19:16:38 ~ 

Data File : C:\DX\DATA\30704F\H2OBLK11.D13 

Method : C:\DX\METHOD\7ANION.met 

ACI Address: 1 System: 1 Inject#: 13 Detector:PED-Cond. 

Analyst : Column: 

Calibration Volume Dilution Points Rate Start Stop Area Reject 

External 1 1 

-------------------------------------------------------------------- 

3600 5Hz 0.00 12.00 1000 

********************** Component Report: A11 Components *********************** 

Pk. 

Num 

Ret 

Time 

Component 

Name 

Concentration Height Area B1. 

Code 

%Delta 

0 0.00 FLUORIDE 

----------------------------------------------------------------------------- 

0.000 0 0 0 0.00 

0 0.00 CHLORIDE 0.000 0 0 0 0.00 

0 

I 

0.00 BROMIDE 0.000 0 0 0 0.00 

0 0.00 NITRATE 0.000 0 0 0 0.00 

0 0.00 SULFATE 0.000 0 0 0 0.00 

Totals 0.000 0 0 

File: H2OBLK11.D13-Samp1e: H2OBLANK 

40 

:1-E 

uS 20 

10 

ES 

0 2 - 4 6 8 10 12 

Minutes 

17 

I .1_ 
Data Reprocessed On 12/06/1994 11:14:21 

Sample Name: H20 BLANK Date: 12/05/1994 19:30:25 

Data File : C:\DX\DATA\30704F\H2OBLK11.D14 

Method : C:\DX\METHOD\7ANION.met 

ACI Address: 1 System: 1 Inject#: 14 Detector:PED-Cond. 

Analyst : Column: 

Calibration Volume Dilution Points Rate Start Stop Area Reject 

External 1 1 

-------------------------------------------------------------------- 

3600 5Hz 0.00 12.00 1000 

********************** Component Report: A11 Components *********************** 

Pk. Ret Component Concentration Height Area Bl. $Delta 

Num Time Name Code 

0 0.00 FLUORIDE 

----------------------------------------------------------------------------- 

0.000 0 0 0 0.00 

0 0.00 CHLORIDE 0.000 0 0 0 0.00 

0 0.00 BROMIDE 0.000 0 0 0 0.00 

0 0.00 NITRATE 0.000 0 0 0 0.00 

0 0.00 SULFATE 0.000 

------------------------------------ 

0 0 0 0:00 

Totals 0.000 0 0 

File: H2OBLK11.D14 Samp/e: H20 BLANK 

W-01 

0 

30 

uS 20 

10 

0 

0 2 - 4 6 8 10 12 

Minutes 

1_1 ^--% 
Data Reprocessed On 12/06/1994 11:07:20 

Sample Name: QC Date: 12/05/1994 19:44:12 ~- 

Data File : C:\DX\DATA\30704F\QC000001.D15 

Method : C:\DX\METHOD\7ANION.met 

ACI Address: 1 System: 1 Inject#: 15 Detector:PED-Cond. 

Analyst : Column: 

-_ - -__--___------------------ ---~____--_--------- ~---_---_ ---_----__ 

Calibration Volume Dilution Poi.nts Rate Start Stop Area Reject 

External 1 

-------------------------------------------------------------------- 

1 3600 5Hz 0.00 12.00 1000 

********************** Component Report: All Components ********************** 

Pk. Ret Component Concentration Height Area B1. %Delta 

Num Time Name 

----------------------------------------------------------------------------- 

Code 

1 1.40 FLUORIDE 0.000 10255385 74735117 1 0.00 

2 2.27 CHLORIDE 0.000 30865532 168156307 1-3.55 

0 0.00 BROMIDE 0.000 0 0 0 0.00 

0 0.00 NITRATE 0.000 0 0 0 0.00 

3 10.47 SULFATE 0.000 

------------------------------------ 

6390129 159439805 1 1:32 

Totals 0.000 47511046 402331230 

File: QC000001.D95 Samp/e: QC 

01 

Minutes 

19 u,,~) 

40 

30 

uS 20 

10 

0 
Data Reprocessed On 12/06/1994 11:09:39 

Sample Name: QC Date: 12/05/1994 19:57:59 

Data File : C:\DX\DATA\30704F\QC000001.D16 

Method : C:\DX\METHOD\7ANION.met 

ACI Address: 1 System: 1 Inject#: 16 Detector:PED-Cond. 

Analyst : Column: 

Calibration Volume Dilution Points Rate Start Stop Area Reject 

-------------------------------------------------------------------- 

External 1 1 3600 5Hz 0.00 12.00 1000 

********************** Component Report: A11 Components 

Pk. Ret Component Concentration Height Area Bl. %Delta 

Num Time Name 

----------------------------------------------------------------------------- 

Code 

1 1.40 FLUORIDE 0.000 10373392 75012529 1 0.00 

2 2.27 CHLORIDE 0.000 31012470 163440320 1-3.55 

0 0.00 BROMIDE 0.000 0 0 0 0.00 

0 0.00 NITRATE 0.000 0 0 0 0.00 

3 10.45 SULFATE 0.000 6519625 

------------------------------------ 

169724835 1 1:16 

Totals 0.000 47905487 408177684 

File: QC000001.D16 Samp/e: QC 

40 

30 

uS 20 

10 

0 

0 2 4 6 8 10 12 

Minutes 

20 

, ,r- 
I1--D-122 

June 2, 1998 

PA N Y 

■■i®.i ■i■■~~~■■■■■■■■ i ■■~■■/" ~■■■■■■■ 

~ i ii■■I i■■■■■■ 

~■■ ~ ~ ■■■■■■■ >~ ■■■■ / "~~~.u~~~" \■■■■■■ 

~ ■■■■■■ \ i■■■■■ 

701 N. MAIN STREET 

LEXINGTON, NORTH CAROLINA 27292 

PHONE 338-248-8541 

TOLL FREE 800-672-6181 

A$G- O-JO 

Mr. Brian Schrager 

Midwest Research Institute 

5520 Dillard Road 

Suite 100 

Cary, NC 27511-9232 

Re: Cleveland County Plant (Grover, N.C.) 

Title V application 

Dear Brian: 

Enclosed is the Title V application that Pine Hall Brick Company filed with NCDHNR 

regarding the above facility. At the time I completed the ICR form I did not have this document 

in my possession. I trust you will find it helpful in your research for this type kiln and 

material at the Cleveland County Plant (Grover, N.C.). 

Respectfully submitted, 

CUNNINGHAM BRICK COMPANY, INC. 

Richard W. Cunningham ~ 

Secretary 

RWC/jh 

Enc.: Report 

~ 
4 

State of North Carolina 

Department of Environment, • 

Health and Ncitural Resources 

Mooresville Regional Office 

James B. Hunt, Jr., Governor 

e~~ 

IDEHNR 

DIVISION OF AIR QUALITY 

September 9, 1997 

Mr. Harold B. Newman 

Pine Hall Brick Co., Inc. 

P.O. Box 836 

Madison, North Carolina 27025-0836 SEP 1 

Subject: Title V Application 

Acknowledgment of Receipt 

Pine HaD Brick Co., Inc. 

Grover, North Carolina 

Cleveland County 

Site No. 03/23/0011. 5 

Air Permit No. 06156R04 

Dear Mr. Newman: 

Your initial Title V permit application was received by this office on August 27, 1997. Your 

application has been assiped the tracking number 2300115.97B. Please refer to this tracldng number 

regarding any questions you have or - - ditional information submitted. Your application will be 

reviewed for completeness within 60 of the received date, at which time you wul receive a 

letter veritiing completeness of your ai - ation or a letter indicating the application was considered 

incomplete and will idendfy any deficie This letter will also indicate the review engineer who 

will review your application. Any qu;. ;n regarding your application should be directed to this 

individual. 

Sincerely, 

Michael S. Landis 

Regional Supervisor 

cc: Jeff Twisdale, 

Regional Files 

GADEM\.AQ\WPDATA\PERS0NAL\K b/B\PERM1797N;'1NEHAL..TV1 

~~4 FAX 7CV, I.W -6C40

Moore!~ Alle, North Carolina 28115 4FC An Equal C-.- )Pr)rtunit~i ) ';'~ ,",T .: - -. icft/eAc';.-)n F-:.,plc ,,'er 

919 North Main Strecit, 

-)ice 704,1, 5.'- 1699 500,16 recycied/ 1 01,16 :-:)st-ccnsurr , e; -.per 
Aw -* 23~,o l t5,975 

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. Pm

. ~

e ~-iall Br~ck 

August 25,1997 

Mr. Michael S. Landis 

DEHNR 

Division of Air Quality 

919 North Main Street 

Mooresville, N. C. 28115 

Reply To: 

PINE HALL BRICK CO., INC. 

Lindsay Bridge Road 

Post Oifce Box 836 

Madison, North Carolina 27025-0836 

Telephone 910-548-6007 

Fax 910-548-1837 

~~ 

~*' ', T r 4.j` 

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~ •••u "• ...- ii_r4.lYlL V~ 

Subject: Title V Permit Ap.plication 

Pine Hall Brick Co., Inc. 

Cleveland County, N. C. 

Air Permit No. 6156R04 

Facility ID No. 03/23/00115 

Dear Mr. Landis, 

In accordance with 15A NCAC 2Q.0501 and 15A NCAC instructions, enclosed are 

four (4) copies of the Title V permit application for the subject facility. 

~ Pine Hall Brick of Cleveland County, N. C. forecasts that it will exceed the 10 ton annual 

emission level for hydrogen fluoride during the fourth quarter of 1997. 

If you have any questions related to the application , please contact Mr. Lewis Slaughter 

of Trigon at ( 910 )-668-0093 or me at ( 910)-548-6007. 

You s truly, 

Harold B. Newman 

RECsIA0 

.:,~ . 

(JAUGwx 9 1997 

, 

~ 

2701 Shorefair Drive. P.O. Box 11044 Winston-Salem. NC 27116-1044 Tal. (910) 721-7300 Fa.r. (910) 725-3946 
Prepared For: 

Pine Hall Brick, Inc. 

Post Office Box 749 

Highway 29 South 

Kin.as Mountain, NC 28086 

Prepared By: 

Trigon En;ineerino,Consultants, Inc. 

Post Office Box 18846 

Greensboro, NC 27419 

August 11, 1997 

-i~ 

:.~ 

s~ 

Title V Applica-=on 

Pine 13all Bric ~.., lnc. 

Yir.gs Mountain, '_~torth Carolina 

Tri~on Jab No. 153-97-062 

I 
".22014 : 

TAB 1 - GEr'ERAL INFORMATION 

Form Al 

Area Map 

Site Plan 

Layout 

Flow Sheet 

TAB 2- ES-1: NATURAL GAS FIRED DRYER/SILN 

Forms B 1 

Forms D3-1 

Forms D3-2 

Forms D3-3 

Forms E4 TSP 

Forms E4 SOZ 

Forms E4 HCL 

Forms E4 HF 

Calculations 

TAB 3- ES-2: ROCK FACING 

Forms B 1 

Forms C2 

Forms D3-1 

Forms D3-2 

Forms D3-3 

Forms E4 TSP 

Calculations 

s 

TAB 4- INSIGNIFICANT FUGITIYE SOURCES ~ 

FS-1, FS-2, FS-3 with Calculations 

TAB 5 - SiJNEWARY INFORMATION =` 

Forms D4 :.~ 

Forms D5 

Forms E1 HF 

Forms E2 

Forms E3 

Forms E5 

Forms E6 

TAB 6- CALEiNDAR YEAR (CY) 1996 MATERIALS USAGE A ~YD ENIISSION 

FACTOR APPLICATIONS 

`~ 
SECTION A 

FACILITY (General Information) '. EM 

REVISED: 04/15/94 AIR QUAUTY SECTION - APPLIC: "A FOR AIR PERMIT TO CONSTRUCTIOPERATE' -'' 

I FACILITY NAME: a^ Hall Brick ComvarrV, Irc. 

MAILING ADDRESS: 634 Lindr Brid e Road, Boz 836 SITE ADDRESS: U.S. 

CITY: Madfson Cm': Grover COUNTY: Cleveland 

STATE 1VC ZIP CODE: 27025 7JP CODE: 38086 

CONTACT PERSON: Harold B. Newman I T1TLE: ATana er, Technical Services 

TELEPHONE: 910-548-6007 FAX 910-548-1837 

OWNER OF FACIUTY: SAAE 

MAILING ADDRESS: 

CITY: STATE: ZIP CODE: 

CONTACT PERSON: Hu hJ. DowdleJr. T1TLE: VicePresidetrt, Operah'ons 

TELEPHONE: 910-548-6007 FAX 910-548-1837 

DESCRIBE TYPE OF OPERATION: BrickMamrfacturin 

SIC CODE(S): 145 DESCRIPTION OF PRIMARY SIC GROUP: Brfck & Structural CZay Tile 

FAC/UTY UTM EAST: OR LATITUDE: 35 

0 

10 58 " COORD/NATES 

UTM NORTH: LONGITUDE: 81 ° ?S 18 " 

HAVE YOU INCLUDED ( ) CONSISTENCY DETERMINATION( SOURCE REDUCTION & RECYCLING FORM 03,3 AND ( ) APPLICATION FEE? 

FAC/UTY rS: (,/ ) T1TLE V FACILRY ( ) NON-TITLE V ( ) SYNTHETIC MINOR 

IF TITLE VlNDICATE APPLlCABILlTY: ~1 2 3 4 5. (C(RCLE ALL THAT ARE APPUCABLE) 

4PPLICAT/ON /S BEING MADE FOR (CHECK ALL THAT APPLY) NOTE (7-10 IND/CATES APPUCABIUTY TO TITLE V FACIL/TIES ONLY?: 

( ) NEW FACILITY ( j ) INITIAL TITLE V PERMIT (TV) ( ) RENEWAL (rV) 

( ) MODIFICATION ( ) NEW FACILITY (TV) ( ) PSD (TV) 

( ) EXISTING EMISSION SOURCE(S) ( ) MINOR MODIFICATION (TV) ( ) NON-ATTAINMENT (TV) 

( ) SIGNIFICANT MODIFICATION (TV) ( ) 112(g) (TV) 

IF APPL/CAT/0N /S BEING MADE FOR ANY OF THE FOLLOWING, FORM A2 MUST BE ATTACHED TO TH/S FORM: 

( ) ADMINISTRATIVE AMENDMENT ( ) CHANGE OF OWNERSHIP ( ) RELOCATION (WfTHIN FACIL(TY) (TV) 

( ) ADMINISTRATIVE AMENDMENT (TV) ( ) CHANGE OF OWNERSHIP (TV) ( ) LIKE-FOR-I.IKE REPLACEMENT 

( ) RENEWAL ( ) RELOCATION (WITHIN FACILITY) ( ) L1KE-FOR-UKE REPLACEMENT (TV) 

( ) 502(b)(10) NOTIFICATION (TV) 

HAVE YOU INCLUDED: FLOW CHART(S) ( ) ROOF DIAGRAM PLANT LAYOUT (,/ ) PLOT PLAN, (,./) AREA DIAGRAM 

CURRE:IVT/PREVIOUS PERMIT NO: 06156 EJPIRATION/DISCONTINUED DATE: Augwt 31, 1997 ,+ 

DO YOU CLAIM CONFIDENTIALITY OF DATA ( ) YES NO (SEE INSTRUCTIONS) 

SIGNATURE OF RESPONSIBLE PERSON OR COMPANY: TITLE: YicePresfderrt, Operadons 6 DATE: 

x 

(TYPED) HughJ. DowdleJr. 

DEPAarMeNT Use ONLY: RECEIVED: ASSIGNED TO: PREMISE NUMBER: 

APPLICATION NUMBER: RETURNED: COMPLETE: REVIEWDATE: 

PERMIT NUMBER: DATE ISSUED: 

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TRIGON ENGINEAING CONSULTANTS. INC. 

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1,030 Btu/cu. ft 

18,447 cu. ft/hr 

..._ 

Potential NG usage : 

Heatin; value : 

NOTES: 

FACTOR #1 - AP-42, SUPPLEMENT F(7/93). SEC 1.3 

FACTOR /r- - EPA 450/2-90-011 

ASSUMPTIONS: 

- TSP, PM10, AND POM ARE AFFECTED BY CONTROL 

'atural Gas Combustion: Criteria and Toffie Air Poliutant Emissions f o ~^ ~' a'I Ceatral Office Version 

NAME OF FACII.ITY : Pinc Hall (Kiln Max) APP 018638 

CITY: ICinSs Moutrain Review Engineer W. w111eu 

COUNTY: Cleveland 

Boiler Input Data 

BoILER TYPE > 21 3 

1- LARGE BOII.ER > 100 mmBtu/hr 

2- SMALL BOILER 10 - 100 mm.Btu 2 

3 - COMMERCIAL. < 10 mmBm/hr 

ACTUAL NG BtJRiYED : 162 mm cu. ft/yr 

.0503 PM Allowable 

FOR POTENTIAL : 0.51 lb/mmBtu 

EN'I'ER BOQ-ER SIZE : 19 mmBrii/ht 9.6 Ib/hr 0 max. iaput 

HOURS OF OPERATION : 8,760 hr/yr .0516 S02 Allowable I 

EiNTER o CONTROL EFF. : 0 0 44 lb/hr (2 tnax. inpu[ 

ACTUAL CRITERIA EiMIISSIONS 

Factor Emission Races 

P011utaIIt (lb poll.11E6 cu. ft burned (lb/yr) (lb/hr) (tpy) 

PM 13.7 2,219 0.25 1.11 

M-10 13.7 2,219 0.25 1.11 

SOx 0.6 97 0.01 0.05 

NOx 140.0 22,680 2.58 11.34 

VOCs 2.8 451 0.05 0.23 

CO 35.0 5.670 0.645631068 2.835 

~ ACTUAL TOXIC EMISSIONS 

Factor Emission Rates 

P011utant (Ib poll./1E12 Btu) (lb/yr) - (lb/hr) (tpy) 

FORMALDEHYDE 220.3 36.8 4.20E-03 0.018 

- HEAT CONTENT OF NG 1030 Btu/cu.ft 

VOCS = TOC*(1-%METHANE) 

Disclaimer 

This spreadsheet is for your use only and should be used with caution. DEHNR does not 

guarantee the accuracy of the information contained. This is a draft spreadsheet and is 

continually revised and updated. It is your responsibility to be aware of the most current 

, ., ~ n 
'atural Gas CombLLstion: Criteria and Toxic Air Pollutant Emissions Ci`fc AGta Ceaaal OPfice Version 

NAME OF FACILITY: 

CITY: 

COUNTY: 

Boiler Input Data 

BOILER TYPE > 

1- LARGE BOILER > 100 mmBcu/hr 

2- SMALL BOII..ER 10 - 100 mmBtu 

3 - COMMERCIAI. < 10 mmBtu/hr 

ACTUAL NG BURNED : 

FOR POTENTIAL : 

ENTER BOILER SIZE : 

HOURS OF OPERATION : 

ENTER c CONTROL EFF. : 

Piae Hall Brick 

Kings Mountaia 

Cleveland 

2 

96 Imm cu. ft/yr 

19 mmBtu/hr 

7,224 hr/yr 

0 % 

APP 018638 

Review Engineer W. willecs 

.0503 PM Allowable I 

0.51 Ib/mmBtu 

9.6 Ib/hr (5 max. i.nput 

.0516 S02 Allowable I 

44 Ib/hr (D max. iapuc 

2 3 

ACTIJAL CRITERIA EiNIISSIONS 

Factor Emission Rates 

P011utant (lb po11.11E6 cu. ft buined Qb/yr) (lb/hr) (tpy) 

PM 13.7 - 1,315 0.25 0.66 

M-10 13.7 1,315 0.25 0.66 

SOx 0.6 58 0.01 0.03 

NOx 140.0 13,440 2.58 6.72 

VOCs 2.8 267 0.05 0.13 

CO 35.0 3.360 0.645631068 1.68 

~ ACTLJAL TOXIC E1VIISSIONS 

Factor Emission Rates 

P011utant (lb poll./1E12 Btu) (lb/yr) - (lb/hr) (tpy) 

FORMALDEHYDE 220.3 21.8 3.02E-03 0.011 

POtential NG usage : 133 mm cu. ft/yr 18,447 cu. ft/hr 

Heating value : 1,030 Btu/cu. ft - 

, 

NOTES: 

FACTOR #1 - AP-42, SUPPLEMENT F(7/93). SEC 1.3 

FACTOR !!2 - EPA 450/2-90-011 

ASSUMPTIONS: 

- TSP. PM10, AND POM ARE AFFECTED BY CONTROL 

- HEAT CONTE:`!'I' OF NG 1030 Btu/cu.ft 

VOCS = TOC*(1- ~aMETHANE) '

Disclaimer 

This spreadsheet is for your use only and should be used with caution. DEHNR does not 

guarantee the accuracy of the information contained. This is a dratt spreadsheet and is 

continually revised and updated. It is your responsibility to be aware of the most current 
PINE HALL BRICK COMPANY, INC. 

TITLE V APPLICATION 

GROVER, NC 

PROCESS AREA: ROCK FACING (ES-2) 

Fired brick are subjected to one of five chipping machines that remove pieces from the face of 

the brick to create the appearance of the irregularities of natural rock. Each rock-facing 

machine is equipped with a vacuum duct to remove dust resulting from the chipping. The dust 

is conveyed to a bagfilter.,The bagfilter is installed outside the building and has 770 sq. ft. of 

filter area. 

4:r 

s 

~ 

~~ 
SECTION' B 

EMISSION SOURC`:": ;t~ ENERAL) 

REVISED: C -W1SIe4 AIR QUALIT'l :: TION 

F671 

r

---- - 

MISSION SOURCE DESCRIPTION: Brick Rock-Facing 0 eration 

- 

EMISSION SOURCE ID NO: gS-? 

CONTROL DEVICE ID NO: RF-3BH-1 I EMISSION POINT ID NO(S): gp-Z 

INDICATE WHETHER THIS SOURCE IS SUBJECT TO ( ) NSPS OR ( ) NESHAP REGULATIONS. 

ALTERNATIVE OPERATING SCENARIO (AOS) NO: 

DESCRIBE PROCESS: 

Fired brick enter machines that chip away pieces causing irregularities fn the surface that simulate natural rockc 

OPERATION DATE: June 1989 

SEASONAL VAR/ATION ('/) JAN-MAR: ?S APR.JUN: ZS JUL-SEP: ZS OCT-DEC: ?S 

.tifilTERldLSEN7ERLWGPROCESS-CO?V77MI0US PROCESS MAX DESIGN 

CAPACITY (UNIT/HR) 

REQUESTED CAPACITY 

TYPE UNITS LIMITATION (UNIT/HR) 

t,fodulnr Rrick TOAIS > > 

M4TERNL4ENTERINGPROCESS-BA11rHOPERATION MAX DESIGN 

CAPACITy (UNIT/HR) 

REQUESTED CAPACITY 

TYPE UNITS LIMITATION (UNfT/BATCH) 

MAXIMUM DESIGN CAPACITY (BATCHES/YR): MAXIMUM DESIGN CAPACITY (BATCHESMR): 

FUEL USED: TOTAL MAXIMUM FIRING RATE (MILLION BTU/HR): 

MAX CAPACITY HOURLY FUEL USE: MAX CAPACITY ANNUAL FUEL USE: 

DESCRIBE ANY MONITORING DEVICES, GAUGES, OR TEST PORTS: 

.;t 

: r .. 

•:~ 

INDICATE ALL REQUESTED STATE AND FEDERALLY ENFORCEABLE PERMIT LIMITS (e.g., hours of operation, material input rates, 

emission rates, etc.) AND DESCRIBE HOW THESE LIMITS ARE MONITORED AND WITH WHAT FREQUENCY. 

COMMENTS: 

Input is limited by the capacity ojthe plant k-iIn capacfty. ~~ 
PINE HALL BRICK COMPANY, INC. 

TITLE V APPLICATION 

GROVER, NC 

PROCESS AREA: NATURAL GAS FIRED-TUNNEL KILN (ES-1) 

Wet, formed and stacked brick on kiln cars continuously pass from pre-dry area to dryer then 

through the kiln. 

Natural gas is the ,fuel source for the heat necessary to fire the brick. The combustion 

gases (and heat) flow counter to the product bricks through the kiln and are emitted from a 

stack at the kiln. The gases contain both the products of N.G. combustion and the airborne of 

the firing process. ' 

This process is the capacity controlling of the facility. Production in CY96 was 

22,208,370 standard brick equivalents. The theoretical maximum capacity is 40,000,000 SBE. 

Consequently, potential is determined based on a ratio of 40,000,000/22,208,370 or 1.ti80/1. 

L. 

/ ~ 
SECTION B FB 1 

EMISSION SOURCE (GENERAL) 

REVISED: 04/15184 AIR QUALITY SECTION 

' vIISSION SOURCE DESCRIPTION: Tunnel Kiln I EMISSION SOURCE ID N0: ES-1 

CONTROL DEVICE ID NO: NA EMISSION POINT ID NO(S): EP-1 

INDICATE WHETHER THIS SOURCE IS SUBJECT TO ( ) NSPS OR ( ) NESHAP REGULATIONS. 

ALTERNATIVE OPERATING SCENARIO (AOS) NO: 

DESCRIBE PROCESS: 

Brick Kiln fired with iVG/LPG. . The hot gasses, including the products of combustion and products of the firing process flow counter to the 

brick flow and are emitted at the kiln stack 

OPERATION DATE: August 1988 

SEASONAL VARlATION (%) JAN-MAR: 25 APR.JUN: 25 JUL-SEP: 25 OCT-DEC: zj 

tL4TERL4LSENTERL'vGPROCESS-CONTINUOUS PROCESS MAX DESIGN 

CAPACITY (UNITIHR) 

REQUESTED CAPACITY 

TYPE UNITS LIMITATION (UNIT/HR) 

Vfoditlar Rricks TOV 

,tiIATERlALSEN7ERINGPROCESS-BATCHOPERATION MAX DESIGN 

CAPACITY (UNIT/HR) 

REQUESTED CAPACITY 

TYPE UNITS LIMITATION (UNIT/BATCH) 

MAXIMUM DESIGN CAPACITY (BATCHESJYR): MAXIMUM DESIGN CAPffiClTY (BATCHES/HR): 

FUEL USED: Natural Gas /Pro ne TOTAL MAXIMUM FIRING RATE (MILLION BTU/HR): 19.0 

MAX CAPACITY HOURLY FUEL USE: 18.-JS mcj MAX CAPACITY ANNUAL FUEL USE 162 mmcf 

DESCRIBE ANY MONITORING OEVICES, GAUGES, OR TEST PORTS: 

T - 

INDICATE ALL REQUESTED STATE AND FEDERALLY ENFORCEABLE PERMIT LIMITS (e.g., hours of operation, material input rates, 

emission rates, etc.) AND DESCRIBE HOW THESE LIMITS ARE MON(TORED AND WITH WHAT FREQUENCY. 

I 

COMMENTS: 

~, ~ 
SECTION C 

CONTROL DEVICE (FABRIC FILTER) LC2 

—/ISED: 04/151,'94 AIR OUALTTY SECTIOIY 

)N'I'ROL DEVICE ID ;VO: RF-3BH-1 CON'iROLS EMISSIONS FROM WHICH EMISSION SOURCE iD u0(S): ES-2 

EMISSION POIM m NO(S): EP-2 POS1770Nlrl SERIE'S OF CONTROLS NO. 1 OF 1 UNI IS 

MANUFACiURFR Mikrocul MODEL NO: 64S 8-20 

ALTER^tATIVE OPERATING SCENARIO (AOS) N0: 

DESCRIBE CON'iROL SYSTEA: Dust laden air is conveyed from picJaup point through the bagf"tlter by fan that pulls a vacuum on the system 

TSP 

POLLUTANT(S) COLLECTED: 

CORRESPONDIIYG EFFICIENCY: 99 % o % q 

EFFICIENCY DETERtitINATION CODE: 2 

BEFORE CONTROL ENtISSION RATE (LB/HR): 200 

AI-'tER CONTROL E-MISSION RATE (LB/HR): 0.2 

PRESSURE DROP (IN. H20): MIN~_ MA?(? WARNING AL,AR:1d? YES_,L NO 

INLET TEMPERATURE (F): MIN MAX OUTLET TEMPERATURE (F): MIN MAX 

INLET aII2 FLOW R.aTE (ACFIV): 3500 

'R TO CLOTH RATIO: 4.5 FILTER SURFACE AREA (FI"_): 770 FIL.TER .ML4?C. OPER.aTING TEMP. (F): 150 

i,TER 14ATERL-XL: Polvester DESCRIBE CLEaNIIYG PROCEDURF.S: 

TIIvIE BETWEEN CLEA.^lING: lScPr ( ) MECHAMCAI. ( ) REVERSE FLOW ( ) SIMPLE BAG COLLAPSE 

CLEAMNG TIhIE: SONIC AIIt PULSE ( ) RIIvGED BAG COLL.aPSE 

( ) OTHFFR: 

DESCRIBE MAIIVTENANCE PROCEDURES: Monthly: Clzeck bags for connectiorts or leakr. Check fan belts and lubricate bearings 

DESCRIBE MOISTURE BLINDQYG, CFiEMICAL RESISTIVTIY, AND/OR SPECIAL OPERATNG COND[TIONS: 

DESCRIBE A1YY MONTI'ORIIYG DEVICES, GAUGES, TEST PORTS, ETC: 

SHOW BY DIAGRau`I THE RELATIONSHIP OF THE CONTROL DEVICE TO ITS EMISSION SOURCE(S): 

~~ 
SECTiON D rD3- 1 SPECIFIC EMISSION SOURCE (EMISSION INFORMATION) 

(•see note in instrudions conceming state air to)dcs regulations) 

~~o~ Da~s~s,a 

AIR QUALITY SECTION 

,I EMISSION SOURCE DESCRIPTION: Tunnel Kiln 

EMISSION SOURCE ID NO: ES-1 I IS THIS SOURCE A FUGITIVE SOURCE? ( ) YES NO 

ALTERNATIVE OPERATING SCENARIO (AOS) NO: 

POLLUTANT 

EMISSION 

FACTOR 

TYPE 

EMISSION RATE IN 

LBS/HR 

EMISSION RATE IN 

POTENTIAL ACTUAL POTENTIAL ACTUAL 

TSP 5 0.25 0.25 2219 1315 

P.W-10 5 0.25 0.25 2219 1315 

SOx 5 0.01 0.01 97 58 

NOx 5 2..i8 2.58 22,680 13,440 

VOC 5 0.05 0.05 451 367 

CO 5 0.65 0.65 5670 3360 

HYDROGE.V CHLORIDE 5 1.57 1.06 13,678 7,649 

HYDROGE.V FLL'ORIDE 5 6.36 4.28 55,726 30,959 

FORtiL4LDEHIDE 5 4.2E-03 3.0E-03 36.8 21.8 

t,f - 

~ 

COMMENTS: 
SECTION D 

SPECIFIC EII ~IISSION SOURCE (EMIISSION INFORil ~1ATION) D3-1 

('see aota in imnvctioas coaceraiag stace air coxics regulatioas) 

AIIZ QUALITY SECTION 

cFn• naii S ~ oa 

EMISSION SOURCE DESCRIPTION: BricaE Roc,t Facing Opemtion 

+ EMISSION SOURCE ID NO: SS-2 I IS THIS SOURCE A FUGITNE SOURCE? ( ) YES (11) NO 

AI.TERNATNE OPERATIIVG SCENARIO (AOS) N0: 

~ EMISSION ~SSION RATE IN EMISSION RATE IN 

FACTOR LBS/HR 

I POLLUTANT TYPE POTENTIAL ACTUAL POTENTIAL ACTUAL 

TSP 2 0.22 0.20 1968 236 

I

PMIO 2 0.011 0.01 98.4 11.8 

I 

. I 

I 

I 

~ 

I 

I ' 

I 

I • • 

.+~ 

.1 

C0M1r1LN 1 J: 

I~ 

~ f 
SECTION D ~? D

SPECIFIC EMISSION SOURCE (REGULATORY ANALYSIS) 

AIR C2UALITY SECTION 

/I SED: 04115154 

EMISSION SOURCE DESCRIPTION: Tunnel Kiln 

EMISSION SOURCE ID NO: ES-1 ALTERNATIVE OPERATING SCENARIO (AOS) NO: 

REGULATED 

POLLUTANT EMISSION AND OPERATING LIMITS 

APPLICABLE 

REGULATION 

TSP 0. 25 LB/HR <17.9 LB/Mt 1 SA NC4C 2D . 0515 

PM-10 NONE NONE 

SOx 5E-04 < 2.3 LBS S02&lM07T! INPUT 1 SA NC9C 2D . 0516 

NOx NONE NONE 

VOC NONE NONE 

CO NONE NONE 

HCL 1. 57 LB/HR > 0.18 LB/HR 1 SA NC4C 2H . 0600 

HF 6.36 LB/RR > 0. 63 LB/DAY, 0.064 LB/ffit 1 SA NCAC 2H . 0600 

FORNL4LDEHYDE 4.2E-03 LB/HR < 0. 04 LB/HR 1 SA NC4C 2H . 0600 

~

. 

: . 

r ... 

COMMENTS: 

~ ~/ 
SECTION D D3-2 

SPECIFIC EMISSION SOURCE (REGULATORY ANALYSIS) 

AIR QUALITY SECTION 

'ISED: W 5/94 

EMISSION SOURCE DESCRIPTION: BrrckRock-FacingOperrrtron 

EMISSION SOURCE ID NO: ES-2 ALTERNATIVE OPERATING SCENARIO (AOS) NO: 

EMISSION AND OPERATING UMITS 

APPUCABLE 

REGULATION 

REGULATED 

POLLUTANT 

TSp 0.1? L&WHR < 4. 0 LBS/FIIZ I5A,VC4C lD . 0513 

~ c Y 

z .r 

COMMENTS: 

,~ ~ 
SECTION D D3-3 

SPECIFIC EMISSION SOURCE (REDUCTION AND RECYCLING ACTIVITIES) 

AIR QUALITY SECTION 

REVISED: 0411 S194 

:MISSION SOURCE DESCRIPTION: Tunnel Kiln 

EMISSION SOURCE ID NO: ES-1 I -m 

REGULATED 

POLLUTANT 

ONGOING SOURCE 

REDUCTION 

ACTIVITIES 

(ENTER CODES) 

QTY. EMITTED 

BEFORE REDUCTION 

(LBS/YR) 

QTY. EMITTED 

AFTER REDUCTION 

(LBS/YR) 

PLANNED SOURCE 

REDUCTION 

ACTIVITIES 

(ENTER CODES) 

TSP NONE NA NA NONE 

AW-10 NONE NA NA NONE 

SOx NONE NA fVA NONE 

NOx NONE NA NA NONE 

vOC NONE iVA NA NONE 

CO NONE NA ,V,4 NONE 

HCL NONE N.4 NA ,VONE 

HF NONE NA ,VA ,VONE 

., 

.~ 

~r. 

COMMENTS: 

1W 
SECTION D D3-3 

SPECIFIC EvIISSION SOURCE (REDUCTION Al~1D RECYCLING ACTIVITIES) 

AIR QUALTTY SECTION 

sVISED: 04J15194 

EMI SION S UR E DESCRIPTI N: SriaE Roc,t FadnQ Oaaation 

E1~IISSION SOURCE ID N0: ES-z 

REGULATED ONGOING SOURCE QTY. EMIZTED QTY. EMPPTED PLANNED SOURCE 

POLLUTANT REDUCTION BEFORE REDUCTION AFrER REDUCTION REDUCTION 

ACTMTIES (I.BS/YR) (LBS/YR) ACTIVITIES 

(ENTER CODES) (ENTER CODES) 

TSP NONE NA NA NA 

I 

® ® 

COMMENTS: 

~ •~ 
SECTION D a 

EIVIISSION POINT 

' FVIS ED: 04115194 AIlt QUALITY SECTION 

EMISSIOIY POINT 

ID NO. 

LIST,ILL QYFORMATION A.SSOCIATHD WiTH F.ACH EMISSION POINT 

EM

HEIGHT (F'17 I E

Q 

 (FTj ~ I 

T 

 ~ I (FI' SE~ I ~ ACFM ~ I ~DQtECiTON~ 

RAIIY CAP? 

(Y OR ,^t) 

e 

COMIIrIENTS: 

,~~~ 
SECTION D 

FACiLITY EMlSSIONS SUMMARY 0 

AaR auaLITY SECTION 

,ISED: W594 TOTAL FROM SPEC/F!C EM1SS10N SOURCE SUMMARIES 

POLLUTANT 

ANNUAL EMISSIONS IN LBS/YR 

CAS NO. ACTUAL POTENTIAL I 

PM 

S02 

1566 

58 

4781 

97 I 

NOx 13,440 22.680 

CO 3360 5670 

I VOC 267 451 

LEAD 0 0 

I RYDROGEY CHLORIDE 7647010 7649 13,768 

RYDROGEN FL UORIDE 7664393 30,959 .SS, 726 

I FORVIALDEHYDE 50000 21.8 36.8 

I 

I 

I 

I 

, 

I 

- 

TOTAL FACIUTY FiRING RATE FOR FOSSiL AND WOOD-FIRED BURNERS: MILLION BTU/HR 

FTOTAL REACTIVE VOC's FROM THE FACIL1lY: 0 LBSIDAY or 96 Total Control or OTHER (specify) 

'MMENTS: 

~ / 
SECTION E El 

TITLE V INFORM. .. . ,ON 

JISED: 04/15/94 AIIt QUALITY SECTION 

II AND ALL SUBSEQUENT E" FORM I D(E2 THROUGH E6~

E V YOU NILTST COMPLETE THIS FORM 

II 

INDICATE HERE IF YOUR FACILITY IS MAJOR FOR TITLE.V BY ( ) CATEGORY OR (V ) EMISSION LEVEL. 

IF MAJOR CATEGORY, INDICATE THE CATEGORY: 

IF MAJOR EMISSION LEVEL, COMPLETE THE FOLLOWIIVG: 

POLLUTANT(S) FOR WHICH THE FACII.ITY IS MAJOR EMISSIOfY RATE (SPECIFY UNiTS) 

HYDROGEN FL UORIDE I S. S TONS/YEAR 

AR& YOU SUB.fECT TO ANY CURRENT MAXIMUM ACHIEVABLE CONTROL TECHNOLOGY STANDARDS (MACTs) OR 

FUTURE MACTs. IF SO, SPECIFY: NnNF. 

LIST ANY ADDITIONAL REGULATIONS WHICH ARE REQUESTED TO BE INCLUDED IN THE PERMIT 

SHIELD AND PROVIDE AN fiXPLANATION FOR THE REQUESTED SHIELD: ' 

REGULATION EXPLANATION 

:y 

/~,~~ 
SECTION E 

TiTLE V INSIGNIFICANT ACTIVITIES SUMMARY E2 

REVtSED: oa/15G4 AIR G2UALITY SECTION 

INSIGNIFICANT ACTIVITIES PER TITLE 15A NCAC 20.0507(b) 

DESCRIPTiON OF EMISSiON SOURCE UNITS 8ASIS FOR EXEMPTiON 

(REF. 15A NCAC 21.0507 (b) 

1 FS-1: Grtndfng & Screenfng BLilding < S TONS !SA NCAC 2Q .0102(b)(2)(E)(i) 

REGULATED 

POL UTANTS 

2. FS 2: Storage & Blending Building <S TONS 1SA NC4C 2Q .0102 (b)(2)(E)rz) 

REGULATED 

POL UTANTS 

3 FS 3: Lkvnp Truck Pit <S TONS 15A NCf1C 20 .0102 (b)(2)(E)(i) 

REGUL4TED 

POL UT.lVT'S 

4, Propane Storage Tank: one 30,000gat.' Exernpted I54 :YC4C20.0102 (b)(1)(D) 

7.

8.

REQUEST FOR INSIGNIFiCANT ACTIVITIES PER TITLE 15A NCAC 20 .05E78 aa 

DESCRIPTION OF EMISSION SOURCE UNITS BASI;fiOR EXEMPTION 

(SEE INSTRUCTIONS) 

1.

2.

3.

' ~ 
SECTION E 

EMISSION SOURCE (INITIAL/RENEWAL TITLE V FAC1L1TY) E3 

REVISED: 04115/94 AIR QUALITY SECTION 

aMISSION EMISSION CONTROL CONTROL EMISSION 

SOURCE SOURCE DEVICE DEVICE POINT ID N0. 

ID NO. DESCRIPTION ID NO. DESCRIPTION or "FUGITIVE" 

_7 _7 _7 
SECTION E 

COMPLIANCE PLAN (METHOD OF COMPLIAlvCE) Q 

V7SED: 04/15/94 

EMISSION SOURCE ID N0. F-7- 1 REGULATED POLLUTarrr 'rcp 

APPLICABLE REGUI.ATION 1 sa nrr'a r 7n ns 7 s 

ALTIItNATIVE OPERATION SCENARIO (AOS) NO: 

~ MONITORING REQUIltEMBNTS 

IS ENHANCED MONITORING APPLICABLE? ( ) YES (-J) NO 

IS ENHANCED MONITORING PROTOCOL ATTACHED? ( )YES ( ~ ) NO 

MONITORING DEVICE TYPE: 

MONITORING LOCATION: 

OTHER MONITOItING METHODS (DESCRIBE IN DETAIL): NONF_' 

GENERALLY DESCRIBE THE FREQUENCY AND DURATION OF MONITORING AND HOW THE DATA WILL BE 

RECORDED (i.e., every 15 minutes, 1 minute instantaneoas readi.nss raken to produce an hourly avera;e): NONE 

TEST METHODS 

REFERENCE TEST METHOD DESCRII'TTON: NnNF_ 

REFERENCE TEST METHOD CITATION: NnNE 

RECORDKEEPING 

DATA (PARAMETER) BEING RECORDED: 

FREQUENCY OF RECORDKEEPING (HOW OFTEN IS DATA RECORDED): Nd 

.~ ' 

REPORTING REQUIREMENTS 

GENERALLY DESCRIBE WFiAT IS REPORTED: 

FREQUEIYCY: ( ) MONTHI.Y ( ) QUARTERLY ( ) ONCE EVFRY 6 

I 1 nlVF PFR YFAR !I/ 1 OTI4F12 (DESCRBE) A c ncrrnWmvrn nv nreiirf' ~,I 
SECTION E 

C OMPLIANCE PLAN (NIETHOD OF C OMPLIANCE) El 

'7SED: 04/15/94 

EMISSION SOURCE M N0. F'.T- I REGULATED POLLUTANT Su/fiir ninriilo 

APPLICABLE REGUI.ATION 1 sA NCa r- 9n ns 7K 

AL,TERNATIVE OPERATION SCENARIO (AOS) NO: 

MONITORING 

IS ENHANCED MONITORING APPLICABLE? ( ) YES N) NO 

IS ENHANCED MONITORING PROTOCOL ATTACFiED? ( )YES N) NO 

MONPTORING DEVICE TYPE: 

MONITORING LOCATION: 

0'I'HER MONITORING METHODS (DESCRIBE IN DETAIL): NQNE' 

GENERALLY DESCRIBE THE FREQUENCY AIVD DUR4TION OF MONITORING AiND HOW THE DATA WILL BE 

RECORDED (i.e., every 15 mimues, 1 minuce insranraneous readings raken co produce an hourly avera,e): NA 

TEST METHODS 

REFERENCE TEST METHOD DESCRIP'I'ION: NnNF_ 

REFERENCE TEST METHOD CITATION: NA 

RECORDKEEPING RE 

DATA (PARAMETER) BEING RECORDED: 

. ., 

FREQUENCY OF RECORDKEEPING (HOW OFTEN IS DATA RECORDED): NA 

~.. 

~ ."• 

REPORTING 

GENER.ALLY DESCRIBE WHAT IS REPORTED: 

FREQUENCY: ( ) MON'TEII..Y ( ) QUARTEtLY ( ) ONCE E`IIItY 6 

( ) ONE PER YEAR ( ~/ ) OTI-IER (DESCRIBE) ASnFTFAL ~S ~rn nv e~n~ in' 
SECTION E 

COMPLLAiNCE PLAN (METHOD OF COMPLIANCE) E4 

'ILSED: 04l15/94 

EMISSION SOURCE ID N0. F.S 1 REGULATED POLLUTAty'i' RynRnr:E Av r747 nRmc 

APPLICABLE REGUI.ATIOty I SA N!'A!' 2FT 06()/) 

ALTEBNATIVE OPERATION SCENARlO (AOS) NO: 

MONTTORING 

IS ENHANCED MONITORING APPLICABLE? ( )YES (4) NO 

IS ENHANCED MONITORING PROTOCOL ATTACHED? ( )YES (4) NO 

MONITORING DEVICE TYPE: 

MONITORING LOCATION: 

OTHER MONITOR]NG METHODS (DESCRIBE IN DETAII.): NQNF 

GENERALLY DESCRIBE THE FREQUENCY AND DURATION OF MONITORING AND HOW THE DATA WII.L BE 

RECOR.DED (i.e., every 15 minutes, 1 minuce insransnneous readings raken co produce an hourly average): NA 

TEST METHODS 

REFERENCE TEST METHOD DESCRIPTION: NONE 

sl REFERENCE TEST METHOD CITATION: N,9 

RECORDKEEPING 

DATA (PA.RAMETER) BEING RECORDED: 

FREQUENCY OF RECORDKEEPING (HOW OFTEN IS DATA RECORDED):NA ._ 

...,~ 

REPORTING 

GENERAI..LY DESCRIBE WHAT IS REPORTED: 

FREQUENCY: ( ) MON'I'HII.Y ( ) QUARTfRLY ( ) ONCE EVERY 6 

~ 

i nwlL' DGD VFSR ( ~ ~ (}TF{TM (pESCRME) ~ C fiC7TDR/f~ 12't+ Dy DGD;/lT ; I / 
SECTION E 

COMPLIANCE PLAlY (METHOD OF COMPLIANCE) E~ 

, WLSED: 04/15/94 

EMISSION SOURCE ID N0. REGUT ATED POLLUTAN'T' Rvnrrnr_FN ff rrnnmE 

APPLICABLE REGULATION i s,a Nra r 7rf n,snn 

ALTIItNATIVE OPERATION SCENARIO (AOS) NO: 

MONITORING 

IS ENHANCED MONITORING APPLICABLE? ( ) YES NO 

IS ENHANCED MONITORIlVG PROTOCOL ATTACHED? ( )YES ( ~ ) NO 

MONITORING DEVICE TYPE: 

MONITORING LOCATION: 

OTHER MONITORING METHODS (DESCRIBE IN DETAII.,): NONF 

GE.YERALLY DESCRIBE THE FREQUENCY AND DURATION OF MONITORING AND HOW THE DATA WILL BE 

RECORDED (i.e., every 15 minuces, 1 minute insranra.neous readings taken to produce an hourly average): NA 

TEST METHODS 

REFERENCE TEST METHOD DESCR.IPTION: NONF' 

REFERENCE TEST METHOD CITATION: NA 

RECORDKEEPING REQUIItEMENTS 

DATA (PA,RAMETER) BEING RECORDED: NnNF 

FREQUENCY OF RECORDKEEPING (HOW OFTEN IS DATA RECORDED): NA 

REPORTING REQUIIZEMENTS 

GENERALLY DESCRIBfi WHAT IS REPORTED: 

FREQUENCY: ( ) MONTHLY ( ) QUAR'IZRI.Y ( ) ONCE EVERY 6 

~ 1 nNF PER YEAR ) OTHER (DESCRIBE) 4S nFTF"'^"'z'^ OV DGDUrP 
SECTION E 

COMPLIANCE PLAN (METHOD OF COMPLIANCE) E4 

--ViSED: Oan s/sa 

EMISSION SOURCE ID NO. E'S-? REGULATED POLLUTANT TSP 

APPUCABLE REGULATION_ 15,4 ur..4C 20 _ osls 

ALTERNATIVE OPERATION SCENARIO (AOS) NO: 

( MONITORING REQUIREMENTS 

IS ENHANCED MONITORING APPUCABLE? ( ) YES (J) NO 

IS ENHANCED MONITORING PROTOCOL ATTACHED? . ( ) YES (,/ ) NO 

MONITORING DEVICE TYPE: 

MONITORING LOCATION:. 

OTHER MONITORING METHODS (DESCRIBE IN DETAIL): NONE 

GENERALLY DESCRIBE THE FREQUEIVCY AND DURATION OF MONITORING AND HOW THE DATA WILL BE 

RECORDED (i.e., every 15 minutes, 1 minute instantaneous readings taken to produce an hourfy average): ?yO~~F. 

TEST METHODS 

REFERENCE TEST METHOD DESCRIPTION: NON-F 

REFERENCE TEST METHOD ClTAT10N: rIONF. 

RECORDKEEPING REQUIREMENTS 

DATA (PARAMETER) BEING RECORDED: 

.., 

FREQUENCY OF RECORDKEEPING (HOW OFTEN IS DATA RECORDED): NA 

4.~ 

~. 

REPORTING REQUIREMENTS 

GENERALLY DESCRIBE WHAT IS REPORTED: 

FREQUENCY: ( ) MONTHLY ( ) QUARTERLY ( ) ONCE EVERY 6 MONTHS 

( ) ONE PER YEAR OTHER (DESCRIBE) 'S ^=D 1 fZVEDBYP RL/R - - 
SECTION E 

T1TLE V COMPLIANCE CERT1FiCAT10N 

/IsED:04115FJ4 

In accordance wfth the provisions of Titte 15A NCAC 2Q .0520 the responsible company offlcial of: 

(COMPANY NAME) PjN , HAT , BgICK CO3. IN . 

(COMPANY ADDRESS)634 fJND EY BRID(rE T)., 836 

(CITrr, NC) M4DISOM 1VC 27025 

(COUNTY) ROCKINGHAM 

(PERMIT NUMBER) 06156 

certifies that 

1. for applicable requirements with which tfie facility is in compiiance, the facility shall continue to comply with 

such requirements; 

2. for applicable requirements that will become effective during the permit term, the facility shall comply with 

such requirements; 

3. for applicable requirements for which the facility is not in compliance at the time of permit issuance, a 

narrative description of how the equipment wiil achieve compliance with the applicable requirements has 

been submitted to the North Carolina Division of Environmental Management; and 

4. the facility shall fulfill applicable enhanced monitoring requirements and submit a compliance certification 

as required by the EPA and 40 CFR Part 64. , 

Schedule for Submission of Compliance Certitication During the Term of The Permit: 

Frequency of Submittal As detererrned by nenxit Beginning / / 

~ y 

The undersigned certifies under the penalty of lawthat all inforrnation and statements provided ii ~,the application, 

based on information and belief formed after reasonable inquiry, are true, accurate, and complete. 

~ 

date 

Signature of responsible company official 

H]igh J. Dowdle Jr. Vice President, Onerationa 

Name, Title of responsible official (Type or print) 

[E] 

6.s.er.a rv 21we.a G. riaen Enew.rvv ca.rs.iR rt. 
SECTION E 

TITLE V COMPLIANCE SCHEDULE 

-VISED:W5194 

COMPLIANCF STATUS WITH RFSPECT TO ALL APPLlCABLE REQUIREMENTS: 

W ill each emission source at your facility be in compliancE with all appiicable requirements at the time of permit 

issuance and comply with these requirements? ( ~ ) YES () NO 

(if no compiete a through f below for each 

requirement for which compliance is not achieved.) 

WII your facility be in compliance with all applicable requirements taidng effeci during the term of the permit and 

meet such requirements on a timely basis? (4) YES () NO 

(if no complete a through f below for each 

requirement for wiiicti compliance is not achieved.) 

a. Identify emission source ID No. , 

b. Identify applicable requirement for which compliance is not achieved: 

c. Narrative description of how compliance wiil be achieved with this applicable requirements: 

d. Detailed Schedule of Compiiance: Ste s Date Exoected: 

-_ 

>~ 

e. Frequency for submittal of progress reports (6 month minimum) 

f. Starting date for submittal of progress reports 

~ L 

Ei.qoi.e iaw. vvve.a w Trydr 6v+'~ ^v co~frm M 

F 
I 14 : 20 Kr1G h1 I NERALS, I NC. P. 02 

~Z oFCc~ 

Narth Cueiina Department af Natural Resources and Comfnvnity Da+elaprnent 

Emironmentsl Manaiement Camrnhslon 

AIR PEILNIIT APPLICATION' pate 1 o! 1 

GENERAL INFaRMATiGN 

/NSTR UCTIONS ON I.I CX 

•To construct 3nd ooertle Air Emisrion Sourcrs snd Controi Derices in iecordance with N. C. Gensral Satutas Chaptar 143, Artida 21. 

PLEASE TYPE OR PRINT. ATTACH APPROPRIATE E.MiSS10N SOURCE AND CONTROL DEYICE FORMS FOR lrACH SOURCE 

LISTED IN ITEM 6 BELOW. 

1. Faciiity'Nartme (Comoany, Estiblishment, Town. Etc.): S1C Code Oate FdR DEHA U5E dNLY 

Kings Mountain 8r1ck (Div, of KMG MineraTs; Inc.) 06/26 89 DATE iEC=ivED: 

2. Sitc Location (St./Rd.JHwy.): Citq Zip Code Counry 

Hwy. 29 South a*. SR2238 Grover 28073 C1eveland 

UTM Narth UTM East UTM Zone 

3. MaitinjAddress (P, 0. Box(St.;Rd.JHwy.): 

P. O. Box 129 

ii

tr State ings Mountai n K.C. Z8086 e (704) 739~3616 de 

4. ~~ rnticanl'Tethnica! Contact: Title Phone with Area Code PER~I~IIT NUMBER: 

Gene Stone Plant Superintenden ~ (704) 937-7431 DATEISSUED : 

5. De ~ erintiun nf nreratian cenducced at above faeiiiiy: 

Structural clay brick manufacturing faciTity, brick kiTn with Combination 

naturaT._gas/rueT oi1 b ~ rners artd associa` ~~ raw~nater ~ aT, for,rtina conv2vfna and 

packaging process equipment 

Lisi each EMISSICN SpURC= and CONTROL DEVIC: for which apvlication is made. Asaignan ID NUMBER toe3eh ernission sour-a 

and controt dcvice whicil uniqucfy identifies that soun:n. At:ach aovroprizte emission sourca and controf device forr,ts for ur.fi. 

EMiSStON SOURCE 10 NO. CONTROL DEVICE ID NO. 

Brick ROCkfaCe Equipment RF-3 Baahouse RF-3-3H-1 

USE 5EPaRATE 514Ee_T(5) IF NEEDED 

.~ `.`~ J .. 

7. Mazimum racitity ooeration: ~Hours/Day 7 Days/Weck ~.•~_.Weeks/Year 

8. Nimc and address oF cn;;necring iirm tl,at prepared appiieation or ptans: 

n/a _ 

y Signa rc ur ibfc rson or c pany ofrici 

~K~~ Date 06/26/89 

Signcr's Namc (TYPE OR PRINT) Tille Phone wittl Arra Code 

Oavid H. Lancast2r P1ant Engineer (704) 739-36I6 

JRM AQ-ZZ 

KIIIA 
0-94 FR I I 4: 21 Kr1G M l NERALS, I NC. F. 03 

~ 

at~~~ 

GENERAL DATA FOR PiiOCESSES OR FU1:L BURNING SOURCES 

~ • page t of 3 

NOTE: 00NOT USE THIS FORM FOR INCtNERATORS, USE FORM "F". 

PLEASE TYPE OR PR1NT. ATTACF{ TO THE GENERAL INFORMnT10N FORM "A". IF APPLICABLE, ATTACH AIR POLLUTION 

CONTROL DEVICE FORM "C'. USE SEPARATE FORM FOR EACJi SOURCE. 

1, Emissinn Source snd ID NQ. (FROM GF.NERAL INFORMATiON FORM "A", ITE4t 6j: 

Brick Rocicfacing equipment RF-3 

Z. Oc3criptPon of Process or Fuef Burnins Source Includ;n6Air Contral Deyice: 

Fugit_ive_dust/particu T ate collection from finfshed brick 

 face texturirt g operation 

t - (; 3. Perrnit App(ication is mide for (G4ECK ONE ONLY): Mori ~'~'-~I -I (p (5(Q 

~ 0() Ncw Source () Exist;n= Source () MadircatPon - Lsst Pcrmit No. 

Comr+,cnceConsiryctia nDa1c _ ~ ~ , 19~- Opention Dete 

1. A1,tzimum Sottrce Oocrition: S Flovrs/Day 5 D2y3/SVeefc 50 _We:lcs/Yeu 

S. Air Conuminant.3 Maximum Actuil Emissions Emission 

Lmittcd: BeforeControl AfterControf Estimite Control 

(Ib/hr) I (Ib/hr) I Method' I Deyica'• 

Con trol 

Emcieney 96 

Particuritcs .......... _... _3 - O.L 4 dacnt7uSe 

Stjirur Dioxida 

Nitrt,sen Dia:iJc....... --•-- ~ - 

C.irl»n Munosidc . . . . . . .. _— _ 

Hydrvcarbuns (VOC). . . . . _ . . _ 

Lcad.... 

~ 

....... . 

Otltcr ( 

Othrr { ) • 

- -- - — - - I --- 

'REFEK 70 4ACK OF GENCRAL 1NFORMATION FORK "A" FOR EMlSS10N ESTIMATION CODE 

••ATTACN AIR CONTiiOL DEVICE FORM I.C. 

6. T yrc of Sourcc: 

CNCCK ONE 

~ (X ) A GcNCRAL PROCESS - Source not covered by B and C befow. (Camplete items 7, 8, 13 tttrough 22) 

D Ge.NERAL PROCE"sS WITh (N-PROCESS FUEL - Sourcr where proQucts of combustfon canvet trt3teriiis heated. 

(Complete Items 7, S, 9, 13, 14 2 18 througs ZZ) . 

() C 1=l;EL FlURN1NG 50URC` (boilers, etc.) - Source witere productt ot combtrstfon uo for IJte primuy purpose of produt:ing heat or pow et by indirect heattransfer. (Complete items9 through 22) 

7. Pruccss Operation: (X ) Continuous () Batdt - Norma! 8uch Tints No. Batehet per Diy 

S. Proccss Namc er?cx Rocxracing equipment 

Materi,als Enterin; Protess': 

(include In-process Solid Fuels) 

A. ._ crusnea ort 

B.._.. ~ 

Max. Re;uested 

Input Rates (tb/hr) ,:'Purnit Input 

Deiigrt ) Actuai,•° Rates (Ib/6r) 

c. ......- - - --- -- — 

o . . .. _ . _- --• --- 

E.

F. • _. _._._.. ----- 

G. . . - • ---• - ._ ...r. - — 

TOTAL WEIGHT ENTERING PROCESS 

J NUT L1ST ANY VOLATILC HYDROCARBONS, USE HYI]ROCARBON EMISSION SOURCES FORM "E" 

~~~ 
Y-20-94 Fn I 14 : 21 KMG ff IiERRLS, [NC, F. 04 

C~00 

DATA FOR PROCESSEa

' 

 OR FUEL HURNING SOURCES 

 ' 

— corrtlnued 

page 3 Or 3 

20. Stack'ar Ern+ission Point Qat;: 

Heiglsc Abo.e Ground (fs.)I Inside Area (so, ft) 

I 

Gas Tempeatzue (De=. F} I Direcsfort or Exit 

(uR, dovm or harizonta!) 

volueretrie FToW Rate Veioeiry (rtajiea) An santpllen pores arasTabiat Is raln ap or ttttter otntruetton orer 

(/4CFM) ( ) No ( ) Yes stuic? ( ) No ( ) Yes, (specdlS ) 

!s sciffoldint avaifable for source ttst;ns? ~ Stacfc ID (Vo. — Soureas wiLti 3 common 

() No () Yes stacfc MsTf hm ttse nm+e srscit rmrnber. 

21. Indleste rnonitorinf and recording instniments installed on srieic: 

() Opacily Monitor () 502 Moniter () NOs 4lonicor () Other 

7.2 Attach or sketels a tfow dJagtam ot the proeess or fud burssing rourrr. 1ncJude air eontrvl deviee(s), (SES JNSTRIJCTJCNS ON 

BACK OF TNtS PAGE): 

~rn i ss+o~ Souac~ R F-3 ~ 

'~utcDt•~c ~ 

Ei.J F}L ~.L~~ ~ F1Ch~lEY 

J=,R-cr 1 CLAlA-TT-1 0I.tSi Col.l.Lc.T1v3 AIaC.T 7 •— 

't y 1pb--.x"lper— 

IDltSi 

'b ►s7n5*L. at•] s 

d14t.t4.r~NE Lj C~otLtc-'te•4

J) 

~.'r cartv E.YoQ 

.::_,.. 

=y S• 

~ commcnb: 

//d 
I41G MINERRLS, INC. P. 04 

(

~~ -oF~~

. 

)R PROCE5SE5 OR FUEL BUANIIYG 50URCE5 —conrinued 

' pa5e 3 of 3 

~ 20. Slacfc'ar Emissia,! Paine Data: 

Ne+ghc Abo.e Ground (ft.)I (nside Area (so, ft) 

I 

Gu Tetnperiturn (De=. F) I Direetion of E~tit 

(up, dmvn or horizontal) 

Volumetric F1ow Rate 

(ACFM) 

Velocitr (ttfset.) Ara sztttpilnt ports s aiTsMe? 1s rafn ap or other obstruction awer 

( ) No ( ) Yes I seaelcl ( ) No ( ) Yes, (sQecify) 

is sciPfold;ns avaifable for source trsting? Stick !D No. — Saurcea with s comrrlon 

( ) No ( ) Yes stack enli hare the s=me suck rnumbet. 

21. Indicale monitorinj 3nd recordinB instrumertts installed on stack: 

() Opacily Monitor () S02 Monit.or () NOx Monitor () Other 

27— Attacfi or tketcft a flow diagrarr of the process or fud buming source. Indude a'u cantrvl derice(s). (SEr iNSTit1JCTi0lVS ON 

BACK OF TNiS PAGE): 

= ! SStetJ SoutZc ~ ~ R F-3 ~ X~~~.a,~`,:~ : 

t.,i i~LL—~ t EIKOAUS'r 

~T1CutJ4-T~. ~ ~uS`C' Co1..tf~cnv.1 n~ac.T 7 

s 

~ 

1111~t~ft~NE ~~ CoLL~ulea 

L~L-T GoNdE`(c~. "Wus' 

b ls7esk.. ata 

'3. Commcnts: 

~~ 
Y-20-94 FRI 14:21 KMG MINERALS, INC. P.05 

AIR POLLUTION CONTROL DEVICE 

page 1 af 3 

LEASE TYPE QR PmNT. ATTACJi Tp GEfVERAIy IIVFORMATIGIV Fi7RJy1 "A". 51JrYt.T GESiGN pATA y SPEGiFICATICNS, AlVO 

AvAILABLE :NGINEERING DRAwtNGS. - 

1. Air Controt Device and 10 Na. (FROM GENERAL INFaRMAT1ON FOItM "A", ITEM 6) 

Baghous2 RF-3-BH-1 • 

Z, if ti+cre are scYcral de.ices 1n series. Jist each unit in series startin` at the emission saures. 

(Z) _ (3) TOTALUNITS Ol1e 

3. (ndicate Ernission Sourct and 10 No, that Control Device(s) is instal(ed on: 

Brick Rockface Eguipment RF-3 

4. Narrativc Descri0tion of Control Oeiicc(s): 

Baghous e- `abri c fi 1 ter 

_.._- -- - •-• ._. 

M ikropul_ Mi k rooulsaire 64S-$-20 

Mar.ufacturcr Model Name Mode! Number , , 

S. Estimated Cost of Controt Device ~ Period of Time Control Oevice is Estimated co be Adequate: 

s.2Q.,004--.- •---- 15 Yurs 

6. Permit Apvlic»tion is madc ror (C:-tECC ONE ONLY): 

Q() Ncw Source () Esistin; 4otu.ca() Modifiation — Last Perrrsit No. 

Commence Construction Oate ~~eu`A'Z`{ ( ,1937 I Operation Datrj'044r-44 L ,19 VL 

7. Emission Parsmcten: PART. SOZ NO,t CO VOC LEAD OTHER OTHER 

PoilUtant(s) COntrolled 9 ) ( ) ( ) ( ) ( ) ( ) 

Etnis.ion Rate 9erore Control (Ibfltr) _ 3 

Emissiort Rate Aftcr Control (Ib(hr) • 

Remaval Eff;cieney Percent N _ 

Particle S;.-c Distribution of Particulatss Enterint Control Devics (: Miaon): 

1•lo 1010•25 aQ '25-5o ZQ90-100 Z5Over 100 

, E. Gas Conditiorts at Controi De+ice; 3150Q WTE,ZMEDiATE LOCATIONS 35TQOLFT 

Fiow Rate (ACFibt a ..__._ 

Tcmperature (Deg. F) a _XM5? ent ~amb„ i ent 

Vcinciry (ft.Jset.) a Du 

pressun: Orop (in. H=0) a 

Maiscure ( e) aG_1 

9. Describc Ultirnatc Oisposil of Caitected Matcrials: 

_. Oispcsalon-site at fa cility solid inarganic inert land f111 area 

10. Stack or Ert+issiott Paint Data: 

FteiRi,t Above inside Area Dirertion oi Exit Are thert obstruetrons av"a stacScT 

Grnund (rt.) (sa. ft.) (up, down, or harizontal) (() No () Yes; (sped6f 

25 1.1 _ uo 

Is sc3frofJing av:ilibte fur sourccs tcsting? Are sampling poru availabtel 

( ) No (X) Yes ( ) No (X) Yes 

11. Comrricnls: 

//-~z 
I 

1 >IF: cs+T 

t 

Posidon In Series 

# of Uni ts 

~ 

*•+ "MULTiCYCLONE" • y 

No. of Canes I Prruure Drop (irt. H20) 

t ~ 

13. 

Erriciency (!'e) Volumetric Flow 

Rate (ACFM) 

,r 

~ 

i' 

"PY-20-94 FRI 14: MINEnALS, INC. P.06 

(

6 cP ~) 

12. 

Efricicncy 

SUPPLEME.YTAL DATA FOR AIR CONTAOL DEyICES 

~~ ~~ 

HFL 

, pste 2 of 3 

••• LYCLONE (MECANICAL SEPA4TOR5) •+• 

Vofumetric Fiovr Pn:ssure Orop (in. H20) Baffles or Lou.ars (sperify) Position In Series 

Rate (ACFiN) # of Unitt 

Cycfone Dimensiona (indhes) Crdone Body Diameter Cydont Body Height (f't.) Crdone Cone Hei¢st (ft) 

Tnlet Outlet I (indtes) 

Wet 9vrnI No, of Nozxles I Liquid Used (speciiy) ~ Ftow Rats (GPM) I Makeup Ra(e (GPM) ~ % Resirwlated 

( ) No ( ) Yes 

A process flow diagram must be attacited if cydone is routed to artother cydone or other equipntettt, show sketch of :ntire system. 

RCCCtE aticIISn •T 

C}+ECX lPPRCriZATE tT,.TLZT CCt1r:91J7.LT:0rt B:LCj+ SKETC?t OTHEA 

cCNf IGURAT2tTN 

~ 

Q!f OiAGRA14 ZIVLET _ I ~ 

AT RZGHT OOof IECIIT 

1 

Lc+uvers inict Dir..cnsion of (ndividua! Outfet Dimension of individuil Ind'triduil Cydone Intet Tempentute 

( ) No ( ) Yes I Cycione (inches) Cyclone (inc.ties) I Diameter (inc.4es) (Oel. F) 

14. •+• "FiLTRATiON" (BAGHOUSE) •** 

0 Eflicier.cy (%) voiumetric Fiow Filter5urfaee Air-to-FiiterArea Ratio 

Rate (ACFM) Ara (sq. ft) (ft.lmin.) 

_ 99 3570 770 1 4.5 acfm/sq. ft, 

TYPE OF FiLTEit FtLTER MATERIAL ' 

Q( } Fabric Fiitcr (BAGHOUSE) () FiberOass () Nyfon 

( ) Pacicrd Bed ( ) Mat Fiiter ( ) Nomex ( ) Teflon 

( ) Pznel Fiiter ( ) Wod ( ) Oacron 

( } Other _ ( ) Cotton ( ) Orfon 

a) OtherDa 1 Yes ter 

No. of ComDartmcntl Time Between CIeanint Iniet Temperaturie 

one (~'2Q seconds (Delmbient 

Pressure Drop (in. H30) 

BAG CLF.ANING 

( ) Mecfunial ( ) Sonie 

() Reverse Flow 0( ) Air Pulse 

( ) Simpie 8as ( ) Rlnqed Bit 

Co((apse Caii3pse 

( ) Gther 

Positton 1n Setia 

# I af ~~_ lJnf ts 

~~. 

15. *+• "AFTERBURNER" (FUME INCINERATOR) ... 

Typc or Aftcrburncr: Elficieney(!r.) Volumetric Fiow Position in 5eries 

( ) Direct Ffame Rate (CFM) 

( ) C # of tJnict atalytie 

( ) Otfher 

Maximurn Burner Ratin; Combustion Chamber Retsntlon Time Fue! Type 

(Miillon BTU/hr) Tentp. (Deg. F) (see.) Usage 

Combustion C}+an+ber Dimensions (Ft.): Lengtfi • Diarneter /~ 
TRIGON ENGINEERING CONSULTANTS, INC. 

Subject Date 

Set up By 

Work Computed By 

Checked By 

Project Job Na Page No of 

_ _~G.'JC`SS ~~=14~_~

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s 

TRIGON ENGiNEERING CONSULTANTS, INC. 

Subject Date 

Set Up By 

Work Computed By 

Checked By 

Project Job Na Page No of 

_ 

f ~1 ,.~ :._.~:. ~i ~ 11 .:~r• ~ ~ ~t .: 5 ~ G _'..: %i~;' t _ ~~ , '~ ~^. . ~~ 

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`~7[~ J 
PINE HALL BRICK COMPANY, INC. 

i°a T LE V APPLICATION 

GROVER, NC 

PROCESS AREA: GRINDING ROOM (FS-1) 

Ball Clay and Black One (MNO2) are delivered into the grinder building by covered truck 

from off-site. Grog is transported by enclosed conveyor from storage to the grinder building. 

The above materials are handled inside the grinder building by front end loader. 

Material is fed to a scaIper followed by four screens. Material passing through the screens is 

suitable for further processing. Oversize (tailings) are conveyed to a hammermill and 

rescreened until correctly sized. 

The maximum grinding capacity is 100TPH. The CY96 average rate was 22.4 TPH. In 

1992 an EPA supervised test was performed on a similar (but lar ger) vented operation at the 

Pine Hall Madison, NC facility. Emission Factors resulting from that test are used here. 

Note, however, that the Grover, NC Materials handling and preparation operations are 

all done in enclosed buildings tfiat have no hoods or exhausts; therefore no emission points. 

Emissions from the buildings (if any) occur from opening of access doors. 

A conservative engineering judgment is that no more than five (5) percent of the 

computed particulates are emitted to atmosphere as fu gitives. 

~ 

6' 
TRIGON ENGINEERING CONSULTANTS, INC. 

Date ~ 

Subject 

,: . a 

Set Up By 

Work /'i : ~ _ ,' = i~= i =. ~ ; ''~~ /%~-i.'T~~".cL,<'; - Computed By 

i Checked By 

,`_ 

Project ~~ ~= ~~ Job Na ~ Z- Page No of 

------------ -- --..------- -- - - - - _ 

; _~,i2oCE- 5 S . A1~ ~1 . :' _ ~le! ti!~i ✓G ~~o.~ ~T= ' /~ ~flLi'~iuv~7c .~.5 

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~ , /.'2U C/G ~= J /_ /'` _ ~ ~ /t ~ %;'•%_ ! ~ ! ri - 

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--- ~ r~ ='T ~,~ _ :.•Y7~ = 47z ~ ? -~-' 7 7:: T= I 

-- ------.- -- - --- - ._ - _ s ~ 

~ 0 5'p Z 7~S `'Z r - - , 

le- _ 

✓_-r"-z 

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A crUN L 6 7a 7614. 75N5 _. 
TRIGON ENGINEERING CONSULTANTS, INC. 

Subject Date 

Set Up By 

Work Computed By 

Checked By 

Project Job No. Page No Z of ~- 

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f~ CO,N S: .~Y /J J7. ✓ = F~ ~ = C ~ ~~= r~ C ~,v.~ f=.SCN~J_=_ T/~=—. 

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. 

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i= Vi7N% 

;~ ~ 
PINE HALL BRICK COMPANY, INC. 

TITLE V APPLICATION 

GROVER, NC 

PROCESS AREA: RAW MATERIAL STORAGE & BLENDING (FS-2) 

Granular materials include kaolin clay, sand, marble dust, shale, ball ciay, ore and grog are 

delivered to the interior of the building. The materials are then weighed in formula proportions 

onto a conveyor and transported to the pug mill operation in the forming, cutting and stacking 

area. The operation capacity is limited to the capacity of the pug mill and kiln operation of 

65,600 ton/yr. 

No calculations are necessary to show insignificance for the following: 

1. Refer to calculation's of maximum potential theoretical TSP for arinding room. 

2. Emission factors are the same. 

3. The maximum theoretical through put at grinding is 876,000 TPY with 516 lb/yr TSP. 

4. Storage & blending (FS-2) capacity is limited to 65,600 TPY. 

s 

, V 

t:b. .4• 

~~ 
PINE HALL BRICK COMPANY, INC. 

TITLE V APPLICATION 

GROVER, NC 

PROCESS AREA: TRUCK DUMP PIT (FS-3) TO CONVEY KAOLIN TO BLENDING 

BUILDING 

Emissions are insignificant fiigitives by the same rationai as blending building (FS-?). 

: y • 

•~ ~r 

s 

"~z 
s 

Table 1 

Product Tonnages 

Pine Hall Brick 

Grover, North CaroIina 

CY 96 Materials Usage 

Product Brick No. Produced Tons Produced 

White (@ 3.28 lbs./SBE) 14,790,152 24,256 

Light Gray 2,215,626 3,634 

Dark Gray 2,438,460 3,999 

Pink 2.764,132 4.533 

Total 22,208,370 36,422 

~.~ 

.-, - 

.~~ 
Table II 

Raw Materials by Product CY96 

Pine Hall Brick 

Grover, North Carolina 

Raw 

Material 

' Total Tons 

Kaolin 

Clay % 

tons 

70 

25,484 

Ball Clay % 

tons 

13 

4,723 

Black 

(Mn02) % 

tons 

6.3 

2,272 

P.H. 

Shale 

% 

tons 

5.5 

2,017 

Grog* % 

tons 

1.8 

651 

Sand* % 

tons 

2 

`728 

Marble 

Dust % 

tons 

1.4 

547 

% 100 

Total tons 36,422 

*NOTE: Fractions may vary slightly as available grog varies. 

es ~ 

eY.s 

.: ~.: 

1-Iz 
TRIGON EIYGINEERING CONSULTANTS• INC. TRIGON eYGINEFRING CONSULTANTS. INC. 

Subjwt 

7 Subject Date 

sa ll.My Setup 3y 

wwk CoMp,,,,d 13, Work Cmputed By 

Ch•eked By Ofeked gy 

•ob Ne I'73 10 -i Z- Pig. No of —ftiM Job NCL Page No Qt 

_764 G

'r cr% 

L 

7. 7-1 

7 ------ - 

42. ::Ll cz- .3772o5= 

A14 7- Z-

,. 

7-1 

/o Zl 

7e. 7' 

A•;c 44 ,v 

2 

/W 4fZ Z. Z>Z 7.Alr 

7 

,-i3 
EMISSION FACTOR SOURCES 

PINE HALL BRICK , INC 

GROVER, NC 

1. TSP=3.38x10"5lb/ton, PM10 = 1.6x10" 5 1b/ton: 

Spreadsheet for stone quarry/gMnite crushing 

NCDHNR January 1 1997. Vozzo and Pendola. 

P.3 truck drop---. See appendix. 

2. TSP=4.63x10"6'tons1ton, PM10=2.19x10-6tons/ton: 

Spreadsheet for stone quarrY/g ranite crushing 

NCDEHNR January 1 1997. Vozzo and Pendola. 

P.3 Conveyor drop to pile. See appendix. 

3. TSP=0.0117 lbs/ton, PM10=0.0011 lbs/ton: 

Based on EPA test at Pine Hall Brick in Madison, NC of October 26 through 

November 7, 1992. See appendix. 

4. TSP=0.03 lb/ton, PM10=0.0015 lb/ton: derived from permit application of June 26, 

1989 that was based on bag filter test of ldlarch 3, 1989. See appendix 

5. Criteria pollutants calculated usin gNCDEHNR central office spreadsheet for natural 

gas. HCL=0.21 lb/ton, HF=0.85 lb/ton were NCDEHNR mandated. 

a 

~ x 

'7V 
FACILITY NAME page 3 o15 

FACILITY ID '/_!. 0. - UM1 

Conveyor Transfer Points • : 

w.t Emis Fdr - dry and wet AGTUAL Emis wf wet Inv POTNL Emis - Title V POTNL Emis 

Amount sopna (Ibslton materiaQ suprsn (TP`f) use wet supm (TPY) (tons per year) 

Conveyor Transfer Pts o[ Hate 179Em1 ISE E= I;:E P= LSE PmIQ ISE EM1Q 

Actual Totat - AII Conveyors' : 0.00294 0.001400 0.000 0.000 ERR ERR ERR ERR Dry 

Irrv. Potential Total (ratio up) : F.RR 0.00010 0.000048 ERR ERR Wat 

T-5 Potential Total (ratio up) : ERR 

'toy corr,eyar ystsfer ponn erouqipus totaMa fram indv. cariveyor trop portnx TiOra v potl is CassA m tatrad wpracty of pYnt at a760 nrs 

Other Operations : 

wet EPA Factors • ACTUAL Emis wl wet Inv POTNL Emis - TiOe V POTNL Emis 

Amount su;;pres. (Ibslton matrl procd) suprsn (TP`() use wet supm (TPY) (tons per year) 

(a) Wet Driliing °: ar$attt L71F.tIls1 ISP a]A Lcia E= ISQ E= 129 2u1t] 

Actual Processed (TPI) 0.5 0.00017 0.00008 0.000 0.000 ERR ERR 0.000 0.000 

Rated Capacity (TP-Hr) 

-vw1 at6V is sss<rr+W to tw '.ar e+d 7rNors mne+aY6 Atld ro eat<e r:oneoL . 

(b) BtasUng - n/a for 1993 Inventory 

(c) Load In - Load Out : Particulate Emissions from Pft bnd Crusher Feeder Drop Operatlons : 

(use Truak unloading : fragmented stone: estimate TSP to be 2.114 x PfN-10) 

must documeeC fPA Factors • ACTUAL Erns %d ww st-0m Itn PpTNL Erns -.I v,*t sqm T-3 POTENTIAL Ems 

Ama,t wetsupp pbsiton matrl proed) (TPr) (TPV) (mnspe•ye.r) 

S!2!A ^J1 P!S fX EMe1 m e= LM 2MI-Q zM Emia m E= 

(1) Truck Loading in Pit 

Actual Tons from pit r_~ 0.0000338 0.000016 0.000 0.000 ERR ERR 0.000 0.000 

Potential Tons from pit 

T-5 Potential Tons from pit 0 ~ 

(2) Truck Drop to Crusher/Grizzly Feed + 

Actual Tons to Feeder O 0.0000338 0.000016 0.000 0.000 ERR ERR 0.000 0.000 

Potential Tons to Feeder 

T-5 Potential Tons to Feeder 0 

)oen Storag_e and Haul Roads (see notes) 

(A) aggregate handling (load in out of piles, acttvity) and storage piles (wind erosion). 

(1) Load In - Load Out : Particulate Emissfons from Storage Drop Operations : 

E (tonstton) _ ( (k(0.0032) ((U/5)"1.3) I ((mJ2)"1.4) ) I 2000 

Portion (9'o as decimao of total production Default narameters : 

~ to washed stone pile : 1.1 : matetiat moisture content (96) (Tab 111.3-1)-m -aeNCreqirasweterspray.useririrange 

(TfTLE V GtLC aSSUME NO STONE W0.SHED) 0.74 : TSP particle size multiplier (430 um) ■ k(Tab.11.2.3-2j (0 3 ao 1.1) 

0.35 : PfW.10 particle siZS multiplier (<10 um) a k 

7.5 : mean wind speed (mph) a U(Tab 112.3-3) 

LIM P64 ] 4 

TonslDrop Ton : 4.63E-06 2.19E-0i 

mastataowxat• TonslOropTon ACTU~iLEtASvwuwtstpm MPOTtv1.ErAS-vdretssprn T~ POTENTtALEers 

M+ant wet Stpp (per equadon) a x wn seon. (TPr) a x we stone (TP1 ) (tw r>•r y.r} 

~sea aatr; C7!<Fmrs 7~SP P~e14 ISE 2m14 7~P E~7 Q ISP )*6a14 

Cor Drop to Pile 

ns to Pile ~ 4.63E-06 2.19E-06 0.000 0.000 ERR ERR O.00Q '' 0.000 

ons to Pile T. 

to Pile 0 

(2) Drop to Truck from Pile 

Actual Tons to Pile 4.63E-06 2.19E-06 0.000 0.000 ERR ERR 0.000 0.000 

Potential Tons to Pila 

T-5 Potential Tons to Pile 0 

(11) Wind Etosion Factor : E (tonstton) _ (0.0714 'k ' (sl1.5) • (D/90) • (drZ35) • (w415) ) / 2000 

Portion (96 as decimaQ of totalroduction DefauR trarameters - 

to washed stone pile : 1.6 : silf content %= s[Tab 112.3-11 

(TITLE V CALC ASsUME No STONE wA.9r+ED) 0.74 : TSP particle size multiplier (<30 um) = k[fab.112.3-2( 

0.35 : PM-10 particle size mu@iplier (<10 um) = k 

30 : storage pile duration ■ D 

245 : dry days per year = d(Fg 112.1-1) 

22 : time wind (%) ~ 12 mph a w / 

M PM:14. 

T....<m..,,. T- e oaaa1aa 6.79E-06 
aUGUST 1993 

.:~ c, • ~ ..~ri 

F1NAL TEST REPORT 

MAIN REPORT 

FO R 

USEPA TEST PROGRAM 

CONDUCTED AT 

PINE HALL BRICK PLANT 

MADISOIV, NORTH CAROLINA 

 USEPA CONTRACT NO. 68-D2-0029 

EMS WORK ASSIGNMENT 6 ~ ~ 

ETS CONTRACT N4. 92-655 o'~ 

5 ~"~- 

~ 
r 

TASI.L 3 . 4-1-2 z 

RIIN NQH3~ 

IIA2': 

S?.NZL,ING DATa 

SII24%RY OP' MET'30D 201: TOTAL FZL't""?Ja= PARTICDI.AT°. AND P.si. ta : 

GRI.*JDIRG—SQREII'lZNG BGILDIaTG 

DI-4tZ01—itl Dl-4001—R3 AV'ERAGE 

10/27/92 10/28/92 10/28/92 

lietered Voluate - cf 62.641 51.108 52.638 55.462 

Total Tsst Time - mia 240 180 I80 200 

i Isckiset:a 98.8 98.4 98.2 98.5 

aiS _ PAP-A2J-%-""'ZRS 

Gas Temperatur8 - oF 72 61 69 67 

Ozygea -% 20.9 20.9 20.9 20.9 

Cartoa Dioxide -• 0.0 0.0 0.0 0.0 

Hoistu: e 1.0 1.0 1.0 1.0 

GAS FLOWRAT3 

Ve3ocity - ft/sec 31.13 33.64 34.87 33.21 

Ac':sal Volume - acft : 23471 26163 27119 25585 

Staadard Volume - dsc:!:= 22709 25891 26414 25005 

TOT?iI. PII,T✓'RABZc PARTIC'JI,AT? ZdISSIONS 

Coaceat=atioa - gr/dscf 0.01166 0.00777 0.01284 0.01076 

r3ass Rate - Ib/hr 2.270 1.724 2.907 2.300 ' 

TOTAL P~1BMISSIONS 

Caaca.at=atioa - gr/dsc: 0.00094 0.00077 0.00072 0.00081 

Mass Ra.te - Ib/hr 0.183 0.171 0.163 0.172 

dn~j ~ Sf~ = ,,~ n 

, 1 r7 ~ ~~ _ / /~ ~ v r~ ,, 

. ~ o , Qoo 8 

2/3 

/r QN '• z ~ - 

. s~w 

Noze: DI is ducr 01 off the Gr iadiag-5c--eeniag buildiag. 

See Aapeadix P.3.1 for detailed field sampliag iaformatica. 

A duct sire of 48.0 iaches was u.eed ia calculatiag flowrat8s. This 

iafor.aatioa was gathered from ETS, Inc. files perta9*+ing to the duc= workt 

~~ 
FACII.TIY ID NO. 2300115 PERMIT NO. 6156R3 

S OLZtCE ID NO. 2 

A BAG FILTER ( ID NO. 2; 770 F"I'2 CLOTH AREA) INSTALLED ON 

ROCICF ACING OPERATION. 

E:1~IISSION SOURCE REFfiREiNCE: 

BAG HOUSE TEST : 3-1-89 - 99 % EFFICIE<VCY 

P.4RTICULATES : 0.2 # / HR 

PM10 .=5% 

BRICK ROCKFACED 1996 : 4 1 800,000 

MAXZWUM PRODUCTION RATE: 11,088 BRICK / HR 

NORMAL PRODUCTION RATE 1996: 42 000 BRICK / HR 

HOLRS OPERATED: 4,800,000 BRICK / 4 7 000 BRICK / HR = 1200 HRS 

EvIIS SIONS : 1996 _ 

'FSP: 1200 HRS ( 0.2 #/ HR )/ 2000 r'r/ TON = 0.12 TONS 

PM 10 : 0.12 TONS ( 0.05 )= 0.006 TONS 

_ '~t U C G 1~ ~ l r :/ ~ /j'f7~ X ~ ~ Z.r ~~ / ~r~ I C I~ • - ~ • ~ C~ TO JV 

.~i . 

Z~ c•c ~~~Tc'N 

SS1 cJs : j 5 ~ = O, Z l~~ffi'Z 

t'dt-! - o,Cs- xc,z 

C r~, 

Ts e 

a 

c nj 3 

— C.cc, -, /~/ !QN 

.cY.• +Y , :.~.._. 

t:r 

., 

F. 7 

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06%23/9; I0:47 F3S iO4 9:37 id:I PIVfi HULL BRICK ZOO2 

Stafie of Nortfi Carolina 

Deparfiment of Environment, 

Hec7ith and Natural Resourcas 

Mooresville Regional Officn 

Jomes B. Hunt, Jr., Govemor 

Jonathcn B. Hawes, SecretQry 0EHHNFZ 

DIVISION OF AIR QUALTTY 

June 17, 1997 

Mr. Harold Newmaa 

Pine Hall Brick Company, Inc. 

Post Office Box 836 

lbtadison, North Caroiina 27025-0836 

Subject HF EmLsioTM+Factor 

Grover, Nortfi Caroljna 

CIeveland Coumty 

031Zi/00115 

Air Permit No. 06156iZ03 

Dear i1&. Newtnan: 

Ia response to your lette; dated Tune 11, 1997, concemin.g the F-znisssion Faztor for HF emissions 

from the abave fac+lity, a;cacls test or a$uorine coatent test oa the clay aQtd/or shale at th.is pIarrt must be 

performed aad resuIts submitted withia 60 days of receipt of this Ietter. If Piae HaI1 Brick Coaipaay, 

Inc. decides to permna a stack test, a pratocol shaIl be submitted to the Division of Air Qualitp. Once 

the testing protocol has beea agnroved, it is mzquested that tlie Compauy advise this Office of the test 

dste so tfrat a member of the ofn-ce sta$'may observe the test 

Please be advised that in order tn avoid a vioMoa of North Caroliaa Administradve Code Title 

15A 2Q .0501, Pine HaII Bsick Compauy, Inc. must submit a?itle V applicarioa to this office before the 

faciIity exceeds the TitIe V thresholds of I00 tons per year of PM10, CO 3NOx, S02 or VOC; 10 toas 

per year of eacfi individuaI hazardous air pollutaat ('m t}zi.s case, W; or 26 tons per year of all bazardous 

air pollutauts combmed The toas per yesr liaut tvok effect December 15, 1996; tberefore; Piae HaIl 

Bricic Company, Ine: shouId submit a Trtle V application before the facility exceects the T' rtle V tiueshoId 

limits for the 12 moath period beghliag December I5, 1996. Tbis testing should be completed as soon 

a.s poss~ble to easure the fadIiry does aot exc ~d this Iimit 

If you have suy quesbons with reference to this matter, please do not hesztate to: contact iNfs. 

Denise Humphries or me at (704) 663-1699. 

1

SIDc° y, z , 

. ' 

~ 

~ 

11~E1 S. LaIIdIs 

Acting Regional Supervisor 

h 

~ 5 

DFFi:sI Y ~ 

rc="AMC,RwPDA IL'l9TOGt7.LC: 
r'1ECt}I 70: 

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~ ~ •~±.! ~ i.. ~

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PINE HALL 3RIC:C CO.. INC. 

Lincsav 8nc;s ?oaa 

Pcst ^'Sce aox 936 

:tac:son. Norm Carotina Z7 OZ-C836 

:aiecror.e 

=:x d ~ C-:18-'83i 

Mr. Nfichael S. Landis 

DEI-LN1R 

Division of Air Quality 

919 North Main Street 

Mooresville , N. C. 28115 

Subject: HF Emissions 

Pine Hail Brick Co. Inc. 

C1eveIand County, North Carolina 

Air Permit No. 06156R03 

Faciiiry ID No. 2300115 

Dear. Nlr. Landis, 

June 11, 1997 

The DEH~i R me:no dated April 30, 1997 states that if data is not available on the actual 

HF emissions from a particular brick plant, a factor of 0.85 ton of &red product must 

be used in preparation of the 1996 Emissiori Inventory. This raises a major concern for 

the Cleveland County facility. 

A comparison of the inventory reported for 1993 with the current report due by June 30, 

1997 utilirin; the 0. 85 r'r/ ton of hred product is shown below. Please be advised that the 

number used in the 1993 inventory was based on an EPA sanctioned test performed at a 

similar brick faciliry in Madison, N. C.. This test work was under USEPA Contract No. 

-1 68-D2-0029 dated Au;ust 1993. Please note this 1993 inventory was submitted and 

approved. 

1993 1996 

Tons of Product 42,272 39,975 

Produced - 

r 

~ ._. . 

HF Emission 0.216 0.85 

Factor : # / Ton 

HF Emission 4.6 Tons 17 Tons 

4F 

ID~ 
As you can see the utilization of the mandated HF factor of 0.35 4 per fired ton zreatly 

effects the status of this plant as far as being a Title V faciIity. Even thou -gh our 

production has decreased some 5% in 1996 the HF emission will be increased by 269 %. 

We will have to report the his,,h factor in the 1996 inventory even though we question the 

accuracy of this number. Please advice us as to what steps we need to take to get an 

accurate number that wiil be acceptable to the state. 

Thank you for your valued guidance and assistance in this matter. 

Sincerely, 

Harold B. Newman 

Nia.nager of Technical Services 

Ceramic Engineer 

CC: Denise F. Humphries 

s 

. ~ 

~~ f 
i - p•,I G7 7r V1•Glrr'I r.G 

C

U N I V E A S I T Y. 

LEN N 

May. 29, 1997 

Mr. Pete Ciesiak 

Executive Director 

9rick Association of the Carolinas 

P. O. 8ox 13290 

Greensboro, NC 27415-3290 

Re: Hydrogen Chioride Reporting Requirements For OEHNR 

Dear Pete: 

In response to the Pcaduction Committee meeting in Sanford yesterday, I have 

reviewed Ilterature informatfon and Center data pertinent to hydrogen chioride 

emissions in brfc a~yf~cturing. The purpose of this letter is to expiain the origin of 

the emissions a d to prov ~e our memoers with an altemative to using the draft AP ~2 

errtission factor of 0.21 ib.! on as required by DEHNR in. the absence of other data. 

The fact t4t# re are chicride emissions in firing has been known for some 

years. De Jonge s s that "chlorides are reieased in flring of sedimentary clay from the 

sea bed" (Ziegelindustrie, 10/86). In the ki(n draft, the gasecus chloride species 

undergoes hydroiysis formirrg HCI. Soiid fueis can contribute to chiorfde .emissions, 

and the emisaion facter for the fuel should be added to that for the raw materfal. 

Arnison presented data on British brick kilns where the practice is to add carban to the 

~ bod}r, and emission factors may be estimated as simiiar to the Belden number 

(Ceramic Industry; 3I92). Unfonunately, there was no cfiioride data in .the Triangte test. 

It is clear that fired bric,ic contain chloride since we are familiar with -some cases 

of effforescence related to chloride and water leaching of fired brick can remove 

chioride. So nat all chtoride is released 'on firing. It is further ciear that a masa batance 

should reveal the site specific amount of chioride reieased on firing. The oniy way to 

do this is to obtain a partial chemicai analysis for ch(oride of both' dried and fired 

products and perform- the mass balance calculation. The data for the dried'product 

must be converted to a"fired weight basis" by dividing the chloride number in the dried 

brfck by the factor (1 - fractional foss on ignition). Any credibie laboratory doing 

traditional wet chemistry can do this. I use Spectrochemical Labs in Piitsburgh (contact 

Tom Futton at 412-371-Z345). 

~ E

10 211 

- - 

;,°yT ~ 3 "C:. E ~ C.ti Z _ R I N C C_ X ~ .rt;C ~.la ~ U:.~ CT..R:YC' 

- t+:.::aze oc :-. -ec-.aq Sc =_._.._c .:.. :: : au+n Ru_:t;.i 3lve ~: :a sei. S: :9625 
.. -' . .. .. ~/ ~ . ~~ rr. . . `..r ~.r ~ a~ `rr. • ~ • 

Mr. Pete Cieslak 

Page 2 

The emissiort faetor in the draft AP-42 documerct camo from the EPA test at 

Belden. There is no HCL data in the test reports for Pine Hall or General Shale. The 

Belden numlber of 0.18 lb.lton was apparently rounded upward to 0.21 Iblton for EPA's 

own reasons. In a draft EPA test report, an analysis ot the Louisville bricic showed mone 

ctrlorida in the fired bricic than the dried brick. 

t beiieve that it is possible that some North Carolina plants toward the Central or 

Westem part of the state cauld find an emission factor on the order - of 0.1 fblton. 

Whether it is worth looking into or whether It is cheaper to pay an emissions levy is up 

to your individual members. 

I hope that this information is helpful, and we remain avaiiabfe to assist as 

necessary. , 

'th bestregard ,- i 

 , . 

, 

Denis A. Brosnan; Ph.D, PE 

Professor and Diractor 

fdab 

`•'~ 

to ~