Brick Kin E• •xhaust 

Merry OaEs, North Carolina 

Tfigon Project No. 0464)6r017. 

April and May 2006 
STATIONARY SOURCE SAMPLING REPORT 

FOR 

TRIANGLE BRICK COMPANY 

MERRY OAKS• NORTH CAROLINA 

BrickKilns 1, 2 and 3 Exhausts 

Performed by: 

Trigon Engineering Consultants, Inc. 

6200 Hands Technology Boulevard 

Charlotte, North Carolina 28269 

704.598.1049 

Trigon Project No. 046-06-017 

April and May 2006 
Stattonary Source Sampling, Triangle Brick Company 

Brick Kilns 1, 2 and 3 Exhausts, Merry July 6. 2006 Oaks, North Carolina Trigon Project No. 046-06-017 

REPORT CERTIFICATION 

This report, the testing details, and the final results have been performed under the supervision and reviewed by the 

shall 

persons named below. Results contained in this report relate only to the items tested. This report not be reproduced in full or in part without the written consent of Trigon Engineering Consultants, 

Date 

Date 

Bryan L. Starnes 

Project Manager 

Air Monitoring Department 

Trigon Engineering Consultants, Inc. 

Signature 

W. Quentin Best 

Quality Assurance Manager 

Air Monitoring Department 

Trigon Engineering Consultants, Inc. 

Paul R. Jenkins, Jr. 

Program Manager 

Air Monitoring Department 

Trigon Engineering Consultants, Inc. 

TRJGON ENGINEERING CONSULTANTS, 1NC. LELAC CERTIFICATE NO. 04036 Page 2 of 19 
Stationary Source Sampling, Triangle Brick Company 

Brick Kilns 1, 2 and 2006 3 Exhausts, Merry Oaks, North Carolina Trigon Project No. 046-06-017 

TABLE OF CONTENTS 

1.0 INTRODUCTION ....................................................................................................................... 4 1.1 Purpose ........................................................................................................ 4 1.2 Outline of Test Program ...................................................................................................... 4 1.3 Test Participants .................................................................................................................. 5 

2.0 PROCESS DESCRIPTION ......................................... 6 2,1 Discussion ...................................................... 

........................................... 6 Figure 1 Process Air Flow Schematic ................................................................ 13 

3.0 SAMPLING METHODS ............................................................... 8 3.1 Sampling Strategy ............................................................................................................... 8 3.2 Sampling and Analytical Procedures .................................................................................. 8 3.3 Sampling Ports, Traverse Points and Cyclonic Flow Determination 8 3.4 Stack Gas Velocity and Volumetric Flow Rate Determination .......................................... 8 3.5 Dry Molecular Weight Determination ................................................................................ 9 3.6 Moisture Determination 10 Particulate Matter, Hydrogen Chloride, and Hydrogen Fluoride Sampling 11 3.9 Sampling Ports and Points 

........................................................... 12 Figure 2 Brick Kiln Nos. 1 & 2 Exhaust ............................................................. 13 Figure 3 Brick Kiln No. 3 Exhaust ............................................................. 14 3.6 Quality Assurance and Quality Control ............................................................................ 15 

4.0 RESULTS ............................................................................... 18 4.1 Summary of Results ............................................................ 

18 4.2 Discussion ......................................................................................................................... 18 

5.0 APPENDICES 

Number of pages in Appendices 117 

A. Summary of Results and Example Calculations 

B. Field Data Sheets 

C. Laboratory Data 

D. Production Data 

E. Calibration Data 

TRJGON ENGINEERING CONSULTANTS, [NC. LELAC CERTIFICATE NO. 04036 Page 3 of 19 
Stationary Source Sampling, Triangle Brick Company 

Brick Kilns 1, 2 and 3 Exhausts, Merry Oaks, North Carolina July 6, 2006 

Trigon Project No. 046-06-017 

1.0 INTRODUCTION 

This section describes the purpose, a brief outline including the sampling and analytical strategy, and the 

personnel involved in the test program. 

1.1 Purpose 

The purpose of this sampling project was to determine concentrations and emission rates of particulate 

matter, hydrogen chloride and hydrogen fluoride from the Brick Kilns 1, 2 and 3 located at the Triangle 

Brick Company facility in Merry Oaks, North Carolina. The results of the sarnpling and the d_oeu_.m_entation 

provided in this report will be used for compliance evaluation according to Air Permit Number 06897T08 

issued by the North Carolina Department of Environment and Natural Resources (NCDENR). 

1.2 Outline of Test Program 

Stationary source sampling was performed on April 20 and May 4, 2006 by the Air Monitoring Department 

of Trigon Engineering Consultants, /ne. (Trigon). On April 20, three 1.5 hour sampling runs were 

conducted at the Kiln 1 and 2 Common Scrubber Stack. On May 4, three 1.5 hour sampling runs were 

conducted at the Kiln 3 Scrubber Stack. The sampling runs were conducted during normal production and 

operating conditions. United States Environmental Protection Agency (US EPA) Methods 1 through 5 were 

used for the determination of particulate matter concentrations and emission rates. Method 26A was used 

for the determination of hydrogen chloride and hydrogen fluoride concentrations and emission rates. The 

specific application of these methods will be described in Section 3.0, Sampling Methods. The sampling 

and analytical procedures used in this test program were those established by the US EPA in standard 

reference test methods and appropriate sampling and analytical procedures. 

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Stationary Source Sampling, Triangle Brick Company July 6, 2006 Brick Kilns 1, 2 and 3 Exhausts, Merry Oaks. North Carolina Trigon Project No, 046-06-017 

1.3 Test Participants 

A list of the project participants, titles, affiliation and telephone numbers can be found below. 

Participant 

Bryan L. Starnes 

Todd R. Phillips 

Larry (Chip) Reynolds 

William G. Colby 

Stephen G. Hall 

Title 

Project Manager 

Senior Environmental 

Scientist 

Senior Environmental 

Scientist 

President 

Environmental 

Engineer 

Affiliation Contact 

Trigon Engineering 

Consultants, Inc. 

Trigon Engineering 

Consultants, Inc. 

Trigon Engineering 

Consultants, Inc. 

Colby Engineering & 

Consulting 

NCDENRDAQ 

Telephone: 704.598.1 049 

Facsimile: 704.598.1050 

E-mail: 

bstarnes@trigoneng.com 

Telephone: 860.491.9664 

Faesimile: 860.491.2211 

E-mail bcolby@optonline.net 

Telephone: 919.791.4200 

Facsimile: 919.571.4718 

E-mail steve.hall@ncmail.net 

TRIGON ENGINEERING CONSULTANTS. INC. LELAC CERTIFICATE NO. 04036 Page 5 of 19 
St•tlo•fary $oU?ce Sampling, Triangle Brick Company 

Brick Kilns 1o 2 and 3 Exhausts, Jury 6. 2006 Merry Oal•, North Carolina Trigon Project lv"•. 

2.0 PROCESS DESCRIPTION 

This section contains a brief description of the brick kiln, the control devices and an air flow schematic. 

2.1 Discussion 

Triangle Brick operates three natural gas fired kilns (Kiln Nos. 1, 2, and 3) at its facility in Merry Oaks, 

North Carolina. Kiln Nos. 1 and 2 vented emissions through a common scrubber CD-K1K2 and Kiln No. 3 

vented emissions through the CD-K3 scrubber control device. A twenty-four car shuttle was conveyed 

through Kilns 1 and 2 yielding approximately 11.855 tons/hr of bricks fired for the April 20, 2006 test. 

During the Kiln 3 test on May 4, 2006, a seventeen ear shuttle was conveyed through the kiln yielding 

approximately 23.776 tons/hr of bricks fired. This production weight information was provided by Kathy 

Wheeler of Triangle Brick. The fiue gases were withdrawn from the gas-fired tunnel(s) through a scrubber, 

I.D. fan, and stack to the atmosphere. Figure 1 details the air flow schematic. 

Production data was recorded by Triangle Brick personnel and is presented in Appendix D. 

TRIGON ENGINEERING CONSULTANTS, INC. LELAC CERTIFICATE NO. 04036 Page 6 of 19 
Stationary•ource•SampllngT•tan•l•Bef• Comp•ny :ub, 6, 200a Brick Kilna 1, 2 and 3 Exhausts, Merry Oaks, North Carolina Trigon Project No. 046-06-017 

Brick Kilns 1, 2 or 3 System 

Atmosphere 

Stack •--Sampling Location 

1.D. Fan 

Scrubber 

Kiln (s) 

Figure 1 

Process Air Flow Schematic 

TRIGON ENGINEERING CONSULTANTS, INC. LELAC CERTIFICATE NO. 04036 Page 7of19 
Stationary Source Sampling, Triangle Brick Company July 6, 2006 Brick Kilns 1, 2 and 3 Exhausts, Merry Oaks, North Carolina Trigon Project No. 046-06-017 

3.0 SAMPLING METHODS 

This section describes the sampling strategy, sampling and analytical methods, and quality assurance/quality 

control procedures implemented during this project. 

3.1 Sampling Strategy 

The sampling and analytical procedures used during this test program were those established by the US 

EPA. The sampling runs were conducted in triplicate to validate the sampling. Tests were conducted 

during normal operating conditions. 

3.2 Sampling and Analytical Procedures 

The US EPA methods used in this sampling program were Method 1 for the location of sampling ports and 

points, and determination of cyclonic flow, Method 2 for volumetric flow rate determination, Method 3 for 

the determination of dry molecular weight of the stack gas, Method 4 for the determination of moisture in 

the stack gas. Methods 5 and 26A were used for the determination of particulate, hydrogen chloride and 

hydrogen fluoride emissions. A sampling and analysis synopsis for these methods is discussed briefly in the 

following subsections. These test methods are available in the Code of Federal Regulations Volume 40, 

Part 60 or by request from Trigon. 

3.3 Sampling Ports, Traverse Points and Cyclonic Flow Determination 

The sampling locations were prepared according to the criteria in Method 1. The duct diameters upstream 

and downstream from the sampling ports were determined prior to sampling. The number of traverse points 

was chosen with respect to sampling port location. For particulate traverses Method 1 specifies a minimum 

of 8 traverse points for sampling ports located >8/>2 downstream/upstream stack diameters from flow 

disturbances and 24 traverse points when located >9/>0.5. The amount of cyclonic flow was determined 

according to the criteria detailed in Method 1. 

3.4 Stack Gas Vdocity and Volumetric Flow Rate Determination 

Method 2 is used for determining the average gas velocity in a stack from measurements of gas density and 

the average velocity head with a Type S (Stausscheibe or reverse type) pitot tube. This method is applicable 

for quantifying gas flows which meet the criteria of Method 1.In principle, measurements of velocity head 

and temperature are performed at the traverse points specified by Method 1. A properly scaled differential 

TRIGON ENGINEERJNG CONSULTANTS, INC. LELAC CERTIFICATE NO. 04036 Page 8 of 19 
Stationary Source Sampling, Triangle Brick Company July 6, 2006 Brick Kilns 1, 2 and 3 Exhausts, Merry Oaks, North Carolina Trigon Project No. 046-06-017 

pressure gauge was selected for the range of Ap values encountered during the traverse. A 0 to 10 inches of 

water inclined manometer was used as the differential pressure gauge. 

During this project, the sampling locations met the criteria detailed in Method 1. Gas stream density was 

determined by Method 3. Moisture determination was performed by Method 4. The principal components 

of the gas velocity measurement system were sequentially: 

• A calibrated stainless steel Type S pitot tube and Type K thermocouple; 

• Leak-free interface tubing between pitot tube and differential pressure gauge; 

• A 0 to 10 inch inclined manometer; and 

• An NIST traceable pyrometer. 

The apparatus was set-up according to manufacturer and reference method recommendations. Pre-test and 

post-test leak checks were conducted using procedures outlined in Method 2, Section 3.1. Velocity head and 

temperature measurements were performed at the traverse points specified by Method 1. The atmospheric 

and static pressure of the stack was also determined for the velocity head readings. The volumetric flow 

rate calculations used were those specified in Method 2, Section 5. A more comprehensive explanation of 

the reference method is detailed in the Quality Assurance Handbook for Air Pollution Measurement 

Systems: Volume III, EPA/600/R-94/038e, (QA Handbook) Field Procedure 2. 

3.5 Dry Molecular Weight Determination 

Method 3 is applicable for determining carbon dioxide and oxygen concentrations and dry molecular weight 

of a sample from a gas stream of a fossil-fuel combustion process. This method may also be applicable to 

other processes where it has been determined that compounds other than carbon dioxide, oxygen, carbon 

monoxide, and nitrogen are not present in concentrations sufficient to affect the results. 

In principle, a gas sample was withdrawn from the emission source by multi-point, integrated sampling. The 

collected sample was then analyzed for percent carbon dioxide, percent oxygen, and percent carbon 

monoxide. The dry molecular weight determination was performed by an Orsat analyzer. 

During this project, the gaseous components were collected using a Method 3 sampling system following 

the analytical procedures outlined in the reference method. The principal components of the sampling 

system were sequentially: 

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Stationary Source Sampling, Triangle Brick Company July 6, 2006 Brick Kilns 1, 2 and 3 Exhausts, Merry Oaks, North Carolina Trigon Project No. 046-06-017 

• A stainless steel probe; 

• A one-way squeeze bulb, to transport the sample to the Tedlar bag; 

• A saturator tube to remove particulate matter and excess moisture; and 

• A leak-free Tedlar bag equipped with a double-end shut-offquick connect. 

The analysis was performed with an Orsat type combustion gas analyzer within 8 hours of sample 

collection. The dry molecular weight was calculated using Equation 3-1, Section 7 of Method 3. The 

analyzer was maintained and operated according to the instructions recommended by the manufacturer and 

in accordance with Method 3 criteria. The analyzer was leak-checked according to Section 6 of Method 3. 

The oxygen reagent was validated by analyzing a sample of ambient air which must meet the specifications 

of 20.9% + 0.3%. 

3.6 Moisture Determination 

Method 4 involves the determination of stack gas moisture. The moisture content is used to correct the 

emission concentration or mass emission rate to a dry basis. EPA Method 4 and FieM Procedure 4 of the 

QA Handbook was used to measure stack gas moisture content. Field Procedure 4 provides detailed 

information on the application of Method 4. 

Preliminary flue gas moisture content (for purposes of setting the isokinetic flow rate) was determined using 

wet bulb/dry bulb thermometers and partial pressure, vapor and saturated vapor pressure equations. This 

technique is described in Method 4 and is summarized below: 

• Moisten the wet bulb thermometer wick with deionized water; 

• Insert both thermometers into the flue gas stream and monitor the wet bulb temperature; 

• When the wet bulb temperature has stabilized, record both the wet bulb and dry bulb 

thermometer temperatures; and 

• Calculate the flue gas moisture content (PMV) using the appropriate equations. 

The moisture content for emission rate calculations was determined in conjunction with the Method 5/26A 

and Method 29 isokinetic sampling trains. The reference method involves the withdrawal of gaseous and 

particulate pollutants from the emission source at an isokinetic rate using a Method 5 sampling system. The 

sampling and analytical procedure for reference Method 4 will be discussed in detail in the following 

sections with the isokinetic sampling procedures. 

TRIGON ENGINEERING CONSULTANTS, INC. LELA C CERTIFICATE NO. 04036 Page 10 of 19 
Stationary Source Sampling, Triangle Brick Company 

Brick Kilns 1, 2 and 3 Exhausts, Merry Oaks, North Carolina July 6, 2006 

Trigon Project No. 046-06-017 

3.7 Particulate Matter, Hydrogen Chloride, and Hydrogen Fluoride Sampling 

Testing for particulate matter, hydrogen chloride, and hydrogen fluoride was performed according to 

Method 26A procedures. Gaseous and particulate pollutants were withdrawn isokinetically from the 

emission source and collected in a multi-component sampling train. In principle, particulate matter that was 

condensed at or above the filtration temperature of approximately 248 degrees Fahrenheit was collected on a 

tared quartz fiber filter. The gaseous components were then bubbled through a measured volume of 0.1N 

sulfuric acid and 0.1N sodium hydroxide to determine the moisture, hydrogen chloride, and hydrogen 

fluoride content of the emission source. The principal components of the sampling system were 

sequentially: 

• A borosilicate glass sample nozzle and probe liner; 

• A heated (248°F +25°F) probe and filter assembly with tared quartz fiber filter; 

• An impinger train consisting of five sequential impingers. Impingers one and two containing 

100 ml each of an absorbing solution consisting of dilute sulfuric acid (0.1N H2SO4). 

Impingers three and four contained 100 ml of dilute sodium hydroxide (0.1N NaOH) followed 

by a final impinger containing 200 grams of silica gel; and 

• A metering system capable of maintaining an isokinetic sampling rate and accurately 

determining the sample volume according to specifications in APTD-0581. 

Sample clean up began immediately after each test run. The filter, which collected the sample, was 

carefully removed from the Teflon filter support and sealed in a Petri dish. The nozzle, probe liner, and 

front filter-half of the filter assembly were rinsed with acetone into a glass storage container, which was 

sealed, and the liquid level marked. The sample containers were transported to Trigon's Air Quality 

Laboratory in Charlotte, North Carolina for particulate matter analysis. 

Hydrogen chloride and hydrogen fluoride were collected in the 0.1N sulfuric acid solution in impingers one 

and two. The liquid in the first two impingers was measured to the nearest milliliter and recorded in order 

to determine the moisture content. The collected sample was placed in a high-density polyethylene (HDPE) 

storage container along with the deionized water rinse of impingers one, two, three and connecting 

glassware. The container was sealed and the liquid level was marked. 

The moisture collected by the silica gel in the sixth impinger was determined to the nearest 0.1 gram. 

Collected condensate measurements were recorded on the "moisture determination and sample recovery 

data analysis" form. The samples were then shipped to Element One Laboratories of Wilmington, North 

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Stationary Source Sampling, Triangle Brick Company July 6, 2006 Brick Kilns 1, 2 and 3 Exhausts, Merry Oaks, North Carolina Trigon Project No. 046-06-017 

Carolina with chain of custody documentation where they were analyzed by ion chromatography. Results 

of the hydrogen chloride and hydrogen fluoride analysis along with Element One's quality assurance data 

package can be found in Appendix C. 

The particulate matter analyses began by transferring the acetone samples to tared beakers. These samples 

were taken to dryness, and then placed in a desiccator along with the filters for an initial drying period of 24 

hours. The particulate mass was determined gravimetrically. The tare weights of the filters and beakers 

were subtracted from the final weights to determine the gross particulate weight. 

An aliquot of the reagent grade acetone was analyzed to determine the blank correction factor. The acetone 

rinse (corrected for the blank) was added to the filter catch to obtain the total particulate weight. The 

particulate samples and method blanks were analyzed by Trigon Engineering Consultants,/ne. personnel. 

The laboratory analyses and chain of custody documentation can be found in Appendix C. 

3.9 Sampling Ports and Points 

The dimensions of the stacks and the location of the sampling ports and points are detailed in Figures 2 and 

3. Method 1 sampling criteria was maintained. The stack cross section for Kiln Nos. 1 and 2 was divided 

into 12 equal areas and the Kiln No. 3 stack was divided into 24 equal areas. The ports for each stack were 

labeled A and B. During the test runs on Kiln Nos. 1 and 2, the traverse points were sampled for 7 minutes 

per point for a run duration of 90 minutes and each point for Kiln No. 3 was sampled for 4 minutes, which 

yielded a total test time of 96 minutes. 

TRIGON ENGINEERING CONSULTANTS, INC. LELAC CERTIFICATE NO. 04036 Page 12 of 19 
Brick Kilns 1, 2 and 3 Exhausts, Merry Oaks, North Carolina Trigon Project No. 046-06-017 

Brick Kiln Nos. 1 and 2 Exhaust 

180" 

K 

>540" 

A B 

SECTION K-K 

63.25" 

K 

Not to Scale 

Figure 2 

Location of Sampling Ports and Points 

TRIGON ENGINEERING CONSULTANTS, INC. LELA C CER, TIFICATE NO. 04036 Page 13 of 19 
Brick Kilns l, 2 and 3 Exhausts, Merry Oaks, North Carolina 

July •, 2oo• 

Trigon Project No. 046°06-0]7 

Brick Kiln No. 3 Exhaust 

>275" 

255" 

A B 

63.0" 

SECTION K-K 

Not to Scale 

Figure 3 

Location of Sampling Ports and Points 

TRIGON ENGINEERING CONSULTANTS, INC LELA C CERTIFICATE NO. 04036 Page 14 of 19 
Stationary Source Sampling, Triangle Brick Company July 6, 2006 Brick Kilns 1, 2 and 3 Exhausts, Merry Oaks, North Carolina Trigon Project No. 046-06-017 

3.6 Quality Assurance and Quality Control 

Trigon has established quality assurance and quality control (QA/QC) guidelines for providing quality 

sampling and analytical data from source tests. These QA/QC procedures were implemented to ensure the 

acceptability and reliability of the data generated. 

In summary, an appropriate degree of data quality was maintained throughout this project. Leak checks and 

isokinetic QA criteria were met. The sampling trains were leak checked prior to and immediately after 

sampling. Leak rates for the isokinetie sampling trains were less than the maximum criterion of 0.02 cubic 

feet per minute. The sampling rates were also within the 100% •:10% criterion. Quality control procedures 

for the particulate matter determinations have included the analysis of an acetone rinse blank, which must be 

less than 0.001% for the acetone residue. Spike and recoveries were performed for the sampling 

methodologies used. An analyte spike was added to a portion of a prepared sample and recovered to within 

70 and 130 percent of the known concentration. The results of the QA criteria for this project are 

summarized in the following tables and can be. Detailed results of the method blanks are reported in 

Appendix C with the laboratory data. 

TRIGON ENGINEERING CONSULTANTS, INC. LEI,,,I C CERTIFICATE NO. 04036 Page 15 of 19 
Stationary Source Sampling, Triangle Brick Company July 6, 2006 Brick Kilns 1, 2 and 3 Exhausts, Merry Oaks, North Carolina Trigon P.roject No. 046-06-017 

Kiln No. 3 Scrubber 

Run 1 Run 3 

26A 1.30% 1.97% 

TRIGON ENGINEEP.ING CONSULTANTS, INC. LELAC CERTIFICATR NO. 04036 Page 16 of 19 
Stationary Source Sampling, Triangle Brick Company 

Brick Kilns 1, 2 and 3 Exhausts, Merry Oak•, North Carolina Trigon Project No. 046-06-017 

Field data and final laboratory results were entered into Trigon's Air Quality Data System by an 

environmental scientist, independently audited by the Project Manager, and reviewed by the Quality 

Assurance Manager for verification of data. After QC review by the QA Manager, the Technical Services 

Manager verified the final report for completeness and reasonableness of data. The report was returned to the 

Project Manager for review and preparation of the final drafL The report requires the signature of the Project 

Manager, Quality Assurance Manager, and the Program Manager before release to the client. Data and final 

reports are archived in a secured area for a minimum period of ten years. 

Trigon's field and laboratory test equipment has been maintained and calibrated in accordance with quality 

assurance procedures established by the US EPA in the QA Handbook. Equipment calibrations including 

pre-test and post-test calibration data are presented in Appendix E. 

TRIGON ENGINEERING CONSULTANTS, INC. LELA C CERTIFICATE NO. 04036 Page 17 of 19 
Stationary Source Sampling, Triangle Brick Company July 6, 2006 

Brick Kiln• 1, 2 and 3 Exhausts, Merry Oaks, North Carolina Trigon Project No. 046-06-017 

4.0 RESULTS 

This section presents a summary of the particulate matter, hydrogen chloride, and hydrogen fluoride 

sampling. Detailed sampling results and example calculations for the test program can be found in 

Appendix A. Field data sheets and sample recovery documentation are presented in Appendix B. 

4.1 Summary of Results 

The table below is a synopsis of the sampling conducted at both locations. 

Summary of Results Kiln Nos. 1 & 2 and Kiln No. 3 

Source Kiln Nos. 1 & 2 Kiln No. 3 

Date April 20, 2006 May 4, 2006 

Emission Rate, Emission Rate, Emission Rate, Emission Rate, 

Pollutants gr/dscf* lbs/hr 

Particulate Matter 0.1161 35.84 

Hydrogen Chloride 0.0012 0.36 

Hydrogen Fluoride 0.0005 0.16 

gr/dscf* 

0.0305 

0,0009 

0.0004 

Ibs/hr 

8.96 

0.27 

0.11 

*grains per dry standard cubic foot 

4.2 Discussion 

This sampling program was performed to demonstrate compliance of the Brick Kiln Exhaust Nos. 1 & 2 

and Brick Kiln No. 3 with regards to Air Quality Permit No. 06897T08 regulations. For sampling Runs 1 

and 2 which were performed on April 20th test for the Kiln Nos. 1 and 2 common scrubber system, the 

particulate matter results yielded a significantly higher emission rate than the emission rate recorded for the 

third sampling run. 

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Brick Kilns 1, 2 and 3 Exhausts, Merry Oaks, North Carolina July 6, 2006 

Trigon Project No. 046-06-017 

5.0 APPENDICES 

This section contains detailed supportive documentation that encompasses the relevant aspects of the 

emission test program. Its contents serve as the foundation for the test report. The emission test report 

presents a summary of the information gathered during the sampling activities. The information contained 

in the appendices is necessary to facilitate the review of the emission test report and determine whether 

proper procedures were used to accomplish the test plan objectives. 

Defensible data and the subsequent pollutant concentrations and emission rates is one of the primary 

objectives of any emission test program. To this end, the test results, example calculations, field data sheets, 

sample recovery, laboratory results, chain of custody documentation, and equipment calibrations have been 

provided to support these objectives. 

TRIGON ENGINEERING CONSULTANTS, INC. LELA C CERTIFICATE NO. 04036 Page 19 of 19 
APPENDIX A 

SUMMARY OF RESULTS AND EXAMPLE CALCULATIONS 

Colby/Triangle Brick 

Merr• Oaks, North Carolina 

?trig_on Pro eot r o;. 0.46:06 017 

Kilns 1 and 2 Common Se•e• •tack 

SUMMARY OF RESULTS 

EPA METHOD 26A 

Determination of Hydrogen Halides & Halogens with Particulate Emissions 

Example Calculations Run 1 

Stack Pressure• Absolute, in. Hg 

Ps P•r + Ps 

Volume Sampled at Stand. Cond., cu. ft. 

17.647 * VM * (P•,,+ AH / 13.6) 

TM + 460 

Volume of Water Vapor at Std. Cond.,SCF 

29.610 

74.830 

Vwc 0.04709 * Vc 

Moisture Content of Gas Stream 

Vwc 

Vsr• + Vwc 

Percent Moisture in Stack 

100 * Vwc 

Pl•v 7 

Vsm + Vwc 

Mole Fraction of Dry Gas 

100 PMv 

100 

Mole. Wt. Stack Gas, Dry Basis, lb/lb mole 

/v• 0.44 * %CO2 + 0.32 * %09_+ 0.28 * (100 %CO2 %02) 

Mole. Wt. Stack Gas, Wet Basis, lb/lb mole 

Ms =/vl• * (1 -Bw,)+ 18.0 * Bw, 

Avg. Stack Velocity, ft/see 

(Ts + 460) 

Vs 85.49 * Cp * APS * SQRT 

(Ps * MJ 

Gas Volume Flow, Dry Std. Cond. CFM 

1058.82 * Vs * A * Ps * (1 Bws) 

SD 

Ts + 460 

Actual Gas Volume Flow, CFM 

QA Vs * A * 60 

Gas Volume Flow, Wet Std. Cond., CFM 

Qsw Qso* [1/(1-Bws)] 

Area of Nozzle, ffl 

A, ((D,/2f * 3.14159)/144 

Percent Isokinetic 

0.0945 * (Ts + 460) * Vsro 

0 * Vs * Ps* (1 B,,.•) * A,, 

6.91 

0.085 

8.5 

0.915 

29.103 

28.164 

52.5 

35604 

68695 

38893 

0.00053 

95.4 

Trigon Engb•ecri•g.Consultants, Inc. 
Colby/Triangle Brick 

Merry Oaks, North Carolina 

Trigon Project No. 046-06-01 

Kilns 1 and2•o•n$•-•]-•f•d¢ 

SUMMARY OF RESULTS 

EPA METHOD 26A 

Determination of Hydrogen Halides & Halogens with Particulate Emissions 

Front Half Analysis -Non-Condensible Particulate Matter 

Non-Condensible Concentration, gr/dscf 

(At Standard Conditions) 

Cs 0.0154 * rr•/VsrD 

Non-Condensible Concentration, gr/acf 

(At Standard Conditions) 

C,, 0.0154 * m, / VM 

Non-Condensible Emission Rate, lbs/hr 

(At Standard Conditions) 

C^• 0.00857 * C, * QsD 

Hydrogen Chloride Concentration and Emission Rate 

Hydrogen Chloride Concentration, ppmv 

C C m / MwHCI * 24.05408 =" 

Hydrogen Chloride Concentration, mg/dscm 

Cm m,gHCl*0.001 /VsrD * 0.0283160502 

Hydrogen Chloride Concentration, gr/dscf 

Cs 0.0154 * m,zHCI *0.001/Vsro 

Hydrogen Chloride Concentration, gr/acf 

(At Standard Conditions) 

C,• 0.0154 * rn•HCl / Vu 

Hydrogen Chloride Emission Rate, lbs/hr 

(At Standard Conditions) 

CAw 0.00857 * C, * QSD 

0.1635 

0.1571 

49.88 

1.89 

2.87 

0.0013 

0.0012 

0.38 

Standard Conditions 68 Deg. F, 29.92 in. Hg 

Trigon E•ineering Consultanls, Inc. 
Colby/Triangle Brick 

Merry Oaks, North Carolina 

Tfigon Project No. 046-06-01' 

Run Number 

SUMMARY OF RESULTS 

EPA METHOD 26A 

Determination of Hydrogen Halides & Halogens with Particulate Emissions 

2 3 Average 

Sample Identification 

Date: 

0 

Pb•r 

P, 

Ps 

V• 

AH 

T• 

Wsr• 

Vc 

Vwc 

Bws 

%02 

%CO2 

%CO 

M• 

Cp 

APS 

T• 

Vs 

A 

QsD 

Q, 

Qsw 

D• 

Net Time of Test, minutes 

Sample Time, 24-hour clock 

Barometric Pressure, in. Hg 

Static Pressure, in. Hg 

Stack Pressure, Absolute, in. Hg 

Actual Meter Volume Sampled, cu. i•. 

Avg. Delta H, in. H20 

Avg. Gas Meter Temp., Deg. F 

Volume Sampled at Stand. Cond., cu. ft. 

Volume of Water Collected, ml 

Volume of Water Vapor at Std. Cond.,SCF 

Moisture Content of Gas Stream 

Percent Moisture in Stack 

Mote Fraction of Dry Gas 

Percent Oxygen, Dry 

Percent Carbon Dioxide, Dry 

Percent Carbon Monoxide, Dry 

Mole. Wt. Stack Gas, Dry Basis, lb/lb mole 

Mole. Wt. Stack Gas, Wet Basis, lb/lb mole 

Pitot Tube Constant 

Avg. Sqrt. Delta P, in. H20 

Avg. Stack Temp., Deg. F 

Avg. Stack Velocity, if/see 

Area Stack, ft 2 

Gas Volume Flow, Dry Std. Cond. CFM 

Actual Gas Volume Flow, CFM 

Gas Volume Flow, Wet Std. Cond., CFM 

Sample Nozzle Diameter, inches 

6017-05 6017-06 6017-07 

05/04/06 05/04/06 05/04/06 

96 96 96 

1107-1257 1332-1518 1539-1723 

29.68 29.68 29.56 29.64 

-0.023 -0.022 -0.023 -0.023 

29.657 29.658 29.537 29.617 

56.056 85.756 86.018 75.943 

1.02 2.38 2.41 1.94 

82.5 88.3 86.1 85.6 

54.257 82.401 82.659 73.106 

109.1 163.5 158.1 143.6 

5.14 7.70 7.44 6.76 

0.086 0.085 0.083 0.085 

8.6 8.5 8.3 8.5 

0.914 0.915 0.917 0.915 

16.77 16.50 16.73 16.67 

2.53 2.73 2.50 2.59 

0.00 0.00 0.00 0.00 

29.076 29.097 29.069 29.081 

28.118 28.149 28.155 28.140 

0.84 0.84 0.84 0.84 

0.627 0.619 0.621 0.622 

327.8 325.9 324.8 326.2 

43.8 43.1 43.3 43.4 

21.65 21.65 21.65 21.65 

34506 34105 34304 34305 

56859 55997 56301 56386 

37773 37291 37394 37486 

0.255 0.313 0.313 0.294 

Trig0n Engineering Consultants, Inc.