EBot"-z.A-i"3 -7/•/o7 ENTEC Services
Pollution Control System Evaluation

and Source Emissions

Testing Boral Brick Muskogee, Oklahoma

DIFF Baghouse Emissions Testing DIFF Out•et-

PM w/HCi

/ HF DIFF inlet

HC! ! HF

July 25, 2007 Entec Project

No.: 27175

16-D Commerce

Avenue

Hueytown,

Alabama

35023 Phone: (205) 491-6676

Fax (205) 491-6614 www.entecservices.comEntec Services, inc. 16-D Commerce

Avenue Hueytown, Alabama

35023 Telephone: (205) 491-6676 Fax: (205) 491-6614 Results of the Ju•y 25, 2007 D•FF Baghouse

Emissions

Testing

for D•FF Out•et

PM w! HCi / HF and DIFF

•r•let

HCI / HF at the Boral Brick facility

•ocated

in Muscogee, Oklahoma Submitted to: Boral Brick

Company P.O. Box 1178 Columbus, Georgia

31902 Attention: Mr. Frank

Porter
Entec Project

No. 27175 Completed By:

Tommy z, Jr. Project Leader Report Submitted

August

3, 2007 Reviewed By:

Tom Lotz Technical Services

Manager

hereby certify to the best of my knowledge

al• fieBd sampling

and laboratory

analysis

performed

for this report is authentic

and accurate,

it has been checked

for compBeteness

and accuracy.Boral Brick

Company
Table of Contents
Section Page No.
Executive Summary 1 Emissions Summary 2 Detailed Test Results 4 Sampling Procedures 11 Location of Test Ports 15 Method 5 / 26A Sampling

Train 17 DIFF Outlet Field Data Sheets 18 Test Run 1 19 Test Run 2 24 Test Run 3 28 DIFF Inlet Field Data Sheets 32 Test Run 1 33 Test Run 2 37 Test Run 3 40 Control Room Production

Data 43 Test Protocol 45 QSTI Certification

Documentation 58 Quality Control

/ Quality Assurance

Procedures 61 Field QA / QC Checklist 66 Meter Orifice Check and Temperature

Check

68 Fyrite / Orsat Standardization 72 Preliminary Traverse

and Cyclonic

Flow Verification

75 Laboratory Analysis 76 Equipment Calibrations 82 Safety Documentation 96 Nomenclature and Test Calculations 98Executive Summary Bora• Brick Company

located

in Muscogee,

Oklahoma

retained

Entec Services,

inc. to perform a particulate

matter

emissions

testing

on the D•FF Baghouse

Testing.

Mr. Tommy Lotz, Jr., Mr. Johnathan

Cochran

and Mr. Ryan Harris of Entec Services,

inc. conducted the testing

on July 25, 2007.

Representing

Boral Brick Company

was Mr. Frank Porter who coordinated

testing

with the control

room production

activity.

Entec Services, inc. encountered

no difficulties

in the field collection

of the samples

or in the laboratory analysis

of the samples.oi

0

1.1_ LI... (1}

= X • O- 0 )7" U.. 0 0 E 0 • •

.=• >., "• •o .• o x • o :• •Detailed Test

ResultsEntec Services, Inc. SOURCE OVERVIEW

SOURCE OWNER: PLANT LOCATION: SOURCE(S) NAME(S): SOURCE(S) CONDITION: SOURCE(S) SHAPE: PROBE WASH CHEMICAL: TEST PERFORMED: REFERENCE METHOD

TESTS:

PROJECT MANAGER ENVIRONMENTAL ANALYST-ASSISTANT OWNER'S REPRESENTATIVE: RULING AGENCY Boral Brick Muskogee, OK Outlet of DIFF Baghouse Compliance Testing Circular Acetone Particulate and HCI / HF Testing Sample Location Volumetric Flow Molecular Weight Moisture Content Particulate HCI/HF Mr. Tim Draheim Mr. Ryan Harris Mr. Frank Porter Oklahoma DEQ
DATES TESTS CONDUCTED: ENTEC PROJECT

NUMBER: 07/25/07 27175 EPA Method EPA Method EPA Method EPA Method EPA Method EPA Method

1234526AENTEC Services,

Inc.
16-D Commerce Ave. Hueytown, Alabama 35023 INPUT TEST DATA
Client: Boral Brick Job No.:

27175 Source: Outlet of DIFF Baghouse Data Input By:

Tommy Lotz, Jr. Field Data Units Test Data Run Number Test Date Time Test Run Began Ended Sampling Time Stack Area Symbol

Military Time minutes 07/25/07 0949-1054 60

2 07/25/07 1135-1240 60

07/25/07 1320-1422 6O

AVERAGE

60 As Ft

30.272

30.272

30.272 Barometric Pressure Pba,

in. Hg

30.06

30.06

30.06

30.06 P9

DnVm in. H20

tm in. H20 inches dcf Stack Static Pressure Pitot Tube Correction

factor

F in. H20

-0.33 0.84 0.986 1.800 0.242 42.105 100.5 1.47

-0.35

Meter Correction

Factor Meter Delta H @ Nozzle Diameter 0.84 0.986 1.800 0.242 41.975 104.0 1.46

-0.29 0.84 0.986 1.800 0.242 41.590 Meter Volume Meter Temperature Avg. Orifice Delta H Impingers Weight Gain (Moisture) &H 103.2 1.40

-0.32 0.84 0.986 1.800

WimpWsgO• 0.242 41.890 102.5 1.45 grams 42.4

41.8

41.0

41.7 grams 8.9

10.1

7.1

8.7 Silica Gel Impinger Weight Gain (Moisture) Oxygen Concentration,

dry basis iCarbon Dioxide Concentration,

dry basis Avg. Sq. Rt. of Delta P Stack Temperature Total Hydrogen

Chloride collected,

mg Total Hydrogen

Fluoride collected,

mg Total particulate

collected (sqrt &P)avg 20.0 20.0 20.0 20.0 CO, %

1.0

0.0

0.0

0.3 (in. Hz0)

0.795

0.790

0.775

0.787
F HCLHF 369.8 372.7 0.92 0.025.9 0.09 372.7 1.00 0.025.9 0.025.8 mgmgmg 371.7 0.67 0.025.9 Below Detection

LimitENTEC Services,

Inc.

Client: Boral Brick Job No.:

27175 Source: Outlet of DIFF Baghouse Data Input By: To•y Lotz, Jr. Description Formulas

Symbol

Units

Calculated Data Run Number 2

3 AVERAGE •ime Began-Ended Military'lime

0949-1054

1135-1240

1320-142; 1. Stack Pressure Pbar P•/13.6 P= in. Hg 30.04

30.03

30.04

30.04 2. Meter Pressure =P•ar &H 113,( Pm in. Hg 30.17

30.17

30.16

30.17 3. Standard Meter Volume 17.64"Y* (V.•'Tm)* (P•=r &H 113.( V,•=ul

dscf 39.421

39.054

38.745

39.073 4a. Standard Volume of Water Vapor Condensed 4b. Standard Volume of Water Collected in Silica Gel :0,0470•VV•m•

V,•==)

=of 1.995

1.967

1.929

1.964 v..•,,=) scf 0.420

0.476

0.335

0.410 B• fraction

0.0577

0.0589

0.0552

0.0573 TB• fraction 11.0665

11.4526

11.4509

11.3233

M= gig-mole M= glg-ntole

=(60•0•)'HF•e*Q• HF qbs•r Ibs•r

0.00

0.00

0.00

0.00 (60#•0)*•*Q, PMR Ib/hr

1.21

1.23

1,21

1.22 =T#P=*[0.002•9*V•¢+ Vm*Y*p•

V. a• 65.522

65.218

64.•2

65,061 =0.0471•W• 5. Moisture Fraction =(Vwclstd) Vws•{=td)ll(Vwd=d)

Vwsgf=td Vmlstd)
=Vr•=•) (TB•|/(1-TB.•) =TV•===/0.04707; 6. Moisture Fraction @ Saturation (Theoretical) 7. Standard Water Volume @ Saturation (Theoretical) 8. Volume of Water @ Saturation (Theoretical) 9. Molecular Weight Of Stack Gas, dry basis

0.32-(o•)+ o.44*(co•)+0o2s*(10o-(oz)-(co•)] 10. Molecular Weight Of Stack Gas, wet basis Md*(1-B•=)+18.0"(I•=} 11. Average Stack Gas Velocity 12. Stack Gas Flow @ Stack Conditions

85.49'G=*(sqrt •P)•g'SQRT((T.)

(Ps'Mw)) 60.vs*A• Q.*(T•/Ts)-(p=/p=• 13. Stack Gas Flow @ Standard Conditions •4. Stack Gas Flow @ Dry Standard Conditions 14b. Hydrogen Chloride concentration @ Std.Cond.,Grains/Cu.Ft. =(0.01543*HGL•,)/Q=te 14b. Hydrogen Fluoride concentration @ Std.Cond.,Grains/Cu.Ft. 15. Particulate concentration @ Standard Conditions -43.337

-42.790

-42.452

-42.860 -920.7 -909.1

-901.9

-910.6

15b. Hydrogen Chloride emissions, Ibs per hour 15b. Hydrogen Fluoride emissions, Ibs per hour 21. Particulate emissions 28.960

28.800

28.800

28.853

22. Volume collected through nozzle 28.327

28.164

28.204

28.232 56.38 56.30

55.20

55.958 102,411 102,251

100,252

101,638 65,390 65,061

63,798

64,750 61,615 61,230

60,276

61,040 3.444E-05 3.95tE-04

3.664E-04

2.653E-04
:O'0154•m•m•: 0.0023

0.0023

0,0023

0.0023 =(60r/000)'HCLQ=•*Q== 0.02

0.21

0.19

0.14

24. Isokinetic Sampling Rate, Percent oo*vn (60*v,'A.°e)

% 101.06

100.75

101.53

101.11

Post Meter Odfice Cal. (EMC ALT-009 Yqa) Y, !i ii!i !iii!•!iiiiiiiii .0.:•..9.3.,1,

(•.7..4.

0.9863

0.9923 Below detection limitEntec Services, Inc. SOURCE OVERVIEW
SOURCE OWNER: Boral Bricks PLANT LOCATION: SOURCE(S) NAME(S): SOURCE(S) CONDITION: SOURCE(S) SHAPE: PROBE WASH CHEMICAL: Muskogee,

OK Inlet to DIFF Baghouse Compliance Circular Acetone TEST PERFORMED: REFERENCE METHOD

TESTS:

PROJECT MANAGER HCl / HF Testing Sample Location Volumetric Flow Molecular Weight Moisture Content HCI / HF Mr. Tim Draheim EPA Method EPA Method EPA Method EPA Method EPA Method

123426A

ENVIRONMENTAL ANALYST

TEAM LEADER ENVIRONMENTAL ANALYST

ASSISTANT Mr. Tommy Lotz, Jr. Mr. Johnathan

Cochran OWNER'S REPRESENTATIVE: Mr. Frank Porter RULING AGENCY Oklahoma

DEQ DATES TESTS CONDUCTED: 07/25/07 ENTEC PROJECT

NUMBER: 27175Source: Inlet to DIFF Baghouee Data Input By:

Tommy Lotz, dr. Field Data Run Number Test Date Time Test Run Began Ended Sampling Time Stack Area Barometric Pressure Stack Static Pressure Pitot Tube Correction

factor Meter Correction

Factor Meter Delta H @ ,•lozzle Diameter Meter Volume Meter Temperature Avg. Orifice Delta H Impingers Weight Gain (Moisture) Silica Gel Impinger Weight Gain (Moisture) Oxygen Concentration,

dry basis Carbon Dioxide Concentration,

dry basis •,vg. Sq. Rt. of Delta P Stack Temperature total Hydrogen

Chloride collected,

mg rotal Hydrogen

Fluoride collected,

mg

Symbol

Units

Military Time 0 minutes As Ft P•ar in. Hg
C,
Y.•H@Dn

AHWimp

CO2 (sqrt AP)avg

HCLHF

in. Hz0

in. H20 inches dcfF in. Hz0 grams grams%

mgmg

07/25/07 0950-1055 6O 18.665 30.06 -4.50 0.84 0.991 1.822 0.245 44.728 94.61.79 66.7 12.617.03.0 0.961 527.7 11.10 143

Test Data
07/25/07 1135-1240 6O 07/25/07 1320-1425 6O 18.665 18.665 30.06 30.08 -4.50 0.84 0.991 1.822 0.245 46.983 98.4 1.92 76.210.217.03.0 1.009 535.2 7.43156

AVERAGE

6O

30.06

0.991 1.822 0.245 45.167 103.6 1.75 68.37.317.03.0 0.959 531.16.37145 0.991 1.822 0.245 45.626 98.81.82 70.410.017.03.0 0.976 531.3 8.30148ENTEC Services,

Inc. i::iiiiiiiiiiiiiiiiiiiiii•iii::iCommerce::•i::iiiii::iiiiiiAve.iiiiiiii::::::iii::!!iiiHue•town'iii::•ii::i•ii•i•iAlabamaiiiiii;:•::!!i•!•iiiiiiiiii::!iiiiii::i::i::i::i::i::::::iiiii::i::65023 CALCULA'IED TEST DATA Client: Boral Bricks Job No.:

27175 Source: Inlet to DIFF Baghouse Data Input By: Tommy Lotz, Jr. Description Formulas

Symbol

Units

Calculated Data Run Number 2

3 Test Date Time Began-Ended Militaw Time 1. Stack Pressure P•ar Pg/13.6 Ps in. Hg 2. Meter Pressure Pb=r &H 113.6 Pm in. Hg 3. Standard Meter Volume 17-64"Y" (Vm/T•.)* (P•a•+ •,H 113.6 V.•=t=•

dscf 4a. Standard Volume of Water Vapor Condensed =0.0470s'w•p

v•,•

scf 4b. Standard Volume of Water Collected in Silica Gel =o.0471•'W,•

v,•,,,•

scf 07/25/07

07/25/07

07/25/07 0950-1055 1135-1240

1320-1425 29.73 29.73

29.73 AVERAGE

29.73 30.19 30.20

30.19

30.19 42.569 44.421

42.296

43.096 3.139 3.586

3.214

3.313 0.594 0.481

0.344

0.473 5. Moisture Fraction =(Vw•=a• V,s•(=a•)l(V•:•=d•

Vwsgl=d) Vn•=al] S• fraction

0.0806

0.0839

0.0776

0.0807 9. Molecular Weight Of Stack Gas, dry basis

0.32"(o=)+ 0.44=(co2)+o.28*(100-(oz).(co2)]

M= g/g-mole

29.160

29.160

29.160

29.160 10. Molecular Weight Of Stack Gas, wet basis Md*{1-Bws)+18.0*(B•=]

M, g/g-,mole

28.260

28.224

28.294

28.259 11. Average Stack Gas Velocity 85.49"C=*(sqrt &P),v•'SQRT((T=)

(Ps*Mw)) vs ft/s 74.85

78.89

74.71

76.152 12. Stack Gas Flow @ Stack Conditions S0"vs*A, O= acrm 83,821

88,357

83,675

85,284 13. Stack Gas Flow @ Standard Conditions Qa*(T=#Ts)*(Ps/P•t•}

Qs scfm 44,505

46,562

44,277

45 115 14. Stack Gas Flow @ Dry Standard Conditions Q,*(1-Bv, s)*(T=c•Ts)*(PJPst=)

Q• dscfm 40,917

42,657

40,841

41,472 14b. Hydrogen Chloride concentration @ Std.Cond.,Grains/Cu.Ft. =(0.01543*HCLm•)IQ•a

HCLcs grldscf

0.004

0.003

0.002

0.003 14b. Hydrogen Fluoride concentration @ Std.Cond.,Grains/Cu.Ft. =(0.01543*HF•|IQ,u

HFcs gr/dscf

0.052

0.054

0.053

0.053 15b. Hydrogen Chloride emissions, Ibs per hour

=(S0F/000)*HCLQ=t=*Q==

HC! -Ibs/hr Ibs/hr

1.41

0.94

0.81

1.06 15b. Hydrogen Fluoride emissions, Ibs per hour

=(60/'/'000)*HFQs•'Qsm

HF-tbsRtr

Ibs/kr

18.18

19.81

18.52

18.84 22. Volume collected through nozzle =Ts/P,*[0.0026•9*V,¢+

V•,y*pM'r•l

v, acf 87.207

92.014

86.658

88.626 !24. Isokinetic Sampling Rate, Percent 10o"vn/(S0=v=*A•*e]• % 98.86

98.96

98.41

98.74 !i:.i !iii==!:::-=:=.===-:=ii-:i-"ii!i!•!:.!

1.0039

1.0009

1.0063 J % Difference, (Calibration must be within 6% of original Y.factor) :•:;:•:•:•:•:•:•::•::•::•#•::•::::::::•::::•::•::::•::•::•::•::•::•::::•::::•::•::•:•:•:::•:::• -1.54e/•Sampling ProceduresP

roced u res The particulate

and gas emission

rates were determined

using EPA Methods

1-5, and 26A CFR Title 40, Part 60, Appendix

Ao The calibration

and quality

assurance procedures of EPA CFR 40 Part 60 Appendix

A for all methods,

and the "Quality Assurance Handbook

for Air Pollution

Measurement

System"

Volume

III Stationary Source-Specific Methods

were followed

throughout

the duration

of the field and laboratory testing.
The most current

version

for each method

(as described

in the Federal

Register)

was used. Stack Gas Volumetric

Flow Methods

1 and 2 The velocity

of the gas stream

was determined

according

to EPA Reference

Method

1 and 2 by reading

the instantaneous

velocity

head with an inclined

manometer

at each sampling point with a calibrated

S-type pitot tube attached

adjacent

to the sample

nozzle. The stack pressure

was measured

with the static side of an S-type

pitot tube. A calibrated pyrometer

was used to measure

stack temperature

at each sampling

point. The stack was previously

tested for cyclonic

flow according

to EPA Reference

Method

1. Stack Gas Molecular

Weight

Method

3 The carbon

dioxide

and oxygen

concentrations

were determined

using EPA Reference Method 3 (Fyrite Method).

A sample

of the flue gas was extracted

from the gas stream during each test. These

samples

were analyzed

with a Fyrite gas analyzer.

The molecular weight

of the gas was calculated

using the moisture,

oxygen

and carbon dioxide content

and the measured

stack gas temperature. Moisture Content

Method

4 The moisture

content

used for calculating

the gas stream

flow rate was determined

by measuring the amount

of condensed

moisture

in the glass impingers

in the sampling train as described

in EPA Reference

Method

4 at the completion

of each test. The moisture content

will be conducted

in conjunction

with EPA Method

26A.The moisture

collection

system

consists

of four glass impingers.

The first four impingers
were charged

with 100 ml each with the fourth charged

with silica gel. Ice is placed around the impingers.

The outlet temperature

of the condenser

is monitored

and recorded throughout

the duration

of the testing to verify the temperature

is below 68 o F. Hydrogen Chloride

I Hydrogen

Fluoride

with Particulate

Method

5 / 26A Hydrogen Chloride

/ Hydrogen

Fluoride

with particulate

matter was determined

at the Outlet only. The Inlet was sampled

for Hydrogen

Chloride

/ Hydrogen

Fluoride. Preliminary data was used to determine

stack temperature,

pressure,

and range of velocity heads,

moisture

content

and stack gas dry molecular

weight prior to sampling. The meter box was leak checked

from the pump to the orifice.

Initial and final leak checks of the sampling

system

and pitot lines were performed

as outlined

in Method

5 and will be recorded

on the data sheets.

The nozzle

(glass or Teflon with an angle of taper of 30 degrees

and of button hook design)

was calibrated

before and after the test using a micrometer

and will be also recorded

on the data sheets. The sampling

probe was placed

at each sampling

point to provide

a total sampling

time of at least 60 minutes

and a volume

of at least 31.8 cubic feet. The gases were drawn through a glass nozzle

attached

to a heated

glass lined probe.

The gases

then proceeded through

borosilicate

glass filter holder,

with a Teflon frit filter support

through
a tarred Teflon filter to remove

particulate

matter.

The exit of the filter will be maintained at a temperature

of greater

than 248 0 F. These temperatures

will be recorded

at each point on the data sheets. The gases were then scrubbed

through

a series of four impingers

(optional

impinger

not included) to capture

hydrogen

halides

and halogens

and moisture.

The first and second impingers contained

approximately

100 ml of a 0.1N H2SO4 solution

and the third and fourth impingers

contained

approximately

100 ml of a 0.1 N NaOH solution.

The fifth impinger contained

approximately

250 grams of pre-weighed

silica gel to remove

any remaining moisture.

The gases passed

through

the impinger

series in an ice bath to maintain a maximum

exit temperature

of 68 0 F. This temperature

was recorded

on the data sheets.

The clean and cool gases then entered

the meter box where the gas flow and temperature

were measured.

13The inlet duct configuration,

which is located

vertically

on the top of the circular

duct did not allow for the impinger

train to be connected

to the back of the hot box. An additional ten (10) foot unheated

Teflon

line was used as a jumper

to the impingers

that was securely located

on the platform

below the port. At the completion

of each test run the ten foot jumper

line was cleaned

with distilled

water (DI) into the first impinger

sample recovery bottle.

14Entec Services,

Inc 16 D Commerce

Ave. Hue•town

AL 35023 STACK DRAWING

& TRAVERSE

POINT LOCATION Client: Boral Bricks Job No. 27175 Source: Inletto DIFF Baghouse input By: Tom Lotz, St. Type of Traverse: Velocity (V) or Particulate

(P):

P

Port Type

Nipple

Port Diameter

4 Stack Diameter, inches:

58.5 Stack Area, Ft2: 18.665 Stack Height, feet:

100 Number of Ports: 2 Stack Properties:

Inches

Duct Diameters

Length of Port, inches: 12.50 Upstream Disturbance:

312.0

5.33

Total Number of Traverse Points:

20 Downstream Disturbance:

312.0

5.33

Number of Points per diameter: 10 58.5

312.l: NC.ES

312.0 .c.Es

Point No.

Inside Stack

Outside Nipple Inches Inches 1 1.5 14.0 2 4.8 17,3 3 8.5 21.0 4 13,2 25.7 5 20.0 32.5 6 38.5 51.0 7 45.3 57.8 8 50.0 62.5 9 53.7 66.2 10 57.0 69.5
Adjusted points diameter > 24" no point closer than 1.0 inch Adjusted points diameter < 24" no point closer than 0.5 inch Stack Diameters

between 12-24 inches minimum points are 8 4 points per port if the 8 2 diameters downstream

and upstream criteria is met.

15Entec Services,

Inc 16 D Commerce

Ave. Hueytown,

AL 35023 STACK DRAWING

& TRAVERSE

POINT LOCATION Client: Boral Brick Job No. 27175 Source: Outlet of DIFF Baghouse Input By: Art Otero Type of Traverse: Velocity (V) or Particulate

(P):

P Stack Diameter, inches:

74.5 Stack Height, feet:

100 Stack Properties:

Inches

Duct Diameters Upstream Disturbance:

250.0 Downstream Disturbance:

384.0

3.36 5.15

Port Type

Nipple Stack Area, FtZ: Number of Ports: Length of Port, inches: Total Number of Traverse Points: Number of Points per diameter:Port

Diameter

6 30.27226.502010 74.5 INCHES

0.(• NCHES

Point N•

Inside Stack

Outside Nipple Inches Inches 1.9 8.4 2 6.1 12.6 3 10.9 17.4 4 16.8 23.3 5 25.5 32.0 6 49.0 55.5 7 57.7 64.2 8 63.6 70.1 9 68.4 74.9 10 72.6 79.1
Adjusted points diameter > 24" no point closer than 1.0 inch Adjusted points diameter <_ 24" no point closer than 0.5 inch Stack Diameters between 12-24 inches minimum points are 8 4 points per port if the 8 2 diameters downstream

and upstream criteria is met.

INCHES

16Method 5/26A

Sampling Train

Filter Exit Temperature (>2489 F)

Holder and Probe

• Temperature

• 10#01ml Sensors • 0 1N 1 •;so

Exhaust

npmg,#2100ml 0.1Nt•SO

npmg#3

#4 0.1N 0.1N qaOt qaOt

Impinger Exit Temperature (<68 F)

np IceBath •5-2:;0lic•3 OOO0 • OJ Temp. and Flow Controllers

17