EVALUATION PARTICULATE/HF/HC1 EMISSIONS

TESTING ON THE SCRUBBER/BAGHOUSE

EXHAUST OF TUNNEL KILN #1 BORAL BRICKS,

INC. AUGUSTA PLANT 4 1630 ARTHERN

ROAD Augusta(Richmond County),

Georgia

30901 Project # 02132 October 17, 2002 Testing conducted

for: Mr. David lohnson Environmental Manager Boral Bricks, Inc. PO Box 1178 Columbus, Georgia

31902 (334) 480-2487
ANALYTICAL TESTING

CONSULTANTS,

INC. 301 Brookdale

Street Kannapolis, N. C. 28083 (704) 932-3193

phone (800) 733-3193

toll-free (704) 932-0570

fax corp @ atc-net.net

e-mail www.atc-net.net Web page Distribution: Mr. David Johnson (Three copies) Issue Date: November 14, 2002INTRODUCTION
This report presents

the results of particulate/hydrogen fluoride/hydrogen

chloride

emissions testing conducted

on the scrubber/baghouse

exhaust of the Plant 4 #1 Tunnel Kiln. Evaluation emissions testing via US EPA methods

5/26a was performed

by Analytical

Testing Consultants, Inc. of Kannapolis,

NC. The two man test team consisted

of Dan McCombs

and Kevin Adkins. Testing was completed

on Thursday,

October

17, 2002. Mr. David Johnson

of BoralBricks

was on site during sampling

and was responsible

for collection

of process data. Two separate

runs approximately one-hour

in duration

were conducted.

Changes

to the operation

parameters

of the dry lime scrubber

and the pressure

drop across the baghouse

where made for the two runs labeled seven and eight evaluation. Executive Summary Both runs showed the HF and HC1 emissions

were well below levels contained

in facility Part 70 operating permit (3251-245-0009-V-01-5) of 2.25 lbs per hour. Runs 7 and 8 averaged

0.444 lbs/hr particulate,

<0.008 lbs/hr HF and 0.052 Ibs/hr HC1. Allowable

particulate

emissions

(are based upon total quantities

from the Clay Feed System Conveyor

Belts, Surge Bins, and the Tunnel Kiln #1 [Rule 391-3-1-.02(2)(e)].

CERTIFICATION OF RESULTS "By our signature we certify that the testing and the reporting

of the test results contained

herein are prepared

to the best of our abilities and that, to our knowledge,

the data have been calculated

and reported correctly.

No data or information

has knowingly

been omitted."

W. Keith Poole Laboratory Manager/Technical

Director C. Daniel McCombs Quality Manager/Team

Leader
Page 3 of 78RESULTS SUMMARY

SYSTEM Boral Bricks Tunnel Kiln #1
TEST DATE

10/17/02 PARAMETER Run #4 Run #5 Run #6 GENERAL QS, FLOW, ACFM

48579

49056

47265 Q STD DRY., FLOW SCFM

36802

37304

35847 Vm STD (ft3)

39.49

40.57

38.58 %1 100.50

101.88

100.82
PARTICULATE EMISSIONS PMRc (Ibs/hr)

0.222 Cs (GR/SCFD)

0.0007 HYDROGEN FLOURIDE

EMISSIONS PMRc (Ibs/hr)

<0.007 Allowable (Ibs/hr) HYDROGEN CHLORIDE

EMISSIONS PMRc (Ibs/hr)

0,041 Allowable (Ibs/hr) 0.426 0.0013

<0.006

0.030

0.467 0.0015

<0.007

0.044

AVERAGE

.48300 36651

0.372 0.0012

<0.0072.25

0.0382.25

Page 6 of 202SYSTEM

TEST DATE PARAMETER GENERAL QS, FLOW, ACFM Q STD DRY, FLOWSCFM Vm STD (ft3)%1
PARTICULATE EMISSIONS

RESULTS

SUMMARY Boral Brick Tunnel Kiln # 1 10/17/02R #7E

R #8E

49731 49504 37510 37164 40.33 30.10 100.71 101.16

PMRc (Ibs/hr)

"0.431

0.457 Cs (GR/SCFD)

0.0013

0.0014 HF EMISSIONSPMRc

(Ibs/hr)

<.006

<.009 HCI EMISSIONSPMRc

(Ibs/hr)

0.036

0.069 A VERA GE

49617 37337

0.444 0.0014

<0.008

0.052

Page 5 of 78SAMPLING AND ANALYTICAL

PROCEDURES Particulate/HC1/HF emissions

testing and analysis

were performed

according

to procedures developed bY the U. S. Environmental

Protection

Agency

(USEPA)

and referred

to as Method 5/26A. Sampling

port locations

and number of test points to be used were determined

according to Method

1 and are shown in the data sheets section of this report. The above federal test methods appear in the Code of Federal Regulations

(Reference

1). Test point locations

and sampling

port placement

for velocity

traverses

are shown in the data sheets. Test point locations

were calculated

based upon a 59.25" diameter,

round stack with 2 four inch test ports located ninety degrees apart. Twelve points were sampled

in each test port. An all glass US EPA method

5/26a sampling

train was utilized that employed

glass nozzles and probe liners. A glass filter assembly

held a Teflon filter frit with Teflon filter for determination

of particulate

emissions.

Connections

to the condenser train was a glass "double

el" with a thermocouple

well for measurement

of exhaust temperature ?f the filter. The condenser

train consisted

of five glass impingers

connected sequentially. The first and second impingers

were charged

with 100 ml 0.1 N H2SO4, the third and fourth with 100 ml of 0.1 N H•_SO 4. The fifth impinger

contained

300g of silica gel. All sample recovery

was conducted

on-site by Dan McCombs

and Kevin Adkins.

Condenser

train collections were measured

and rinsed into pre-labeled

amber glass jars. The sulfuric acid fractions were forwarded

to Enthalpy

Analytical,

Inc. a LELAP

accredited

laboratory

(Certificate No. 04010, agency interest no. 85848).

A copy of Enthalpy's

accreditation

is included

in Appendix I. for determinations

of HC1/HF

via US EPA 26a. The sodium hydroxide

fractions were discarded. The front half of the sampling

train was rinsed with reagent grade acetone and stored in 500 ml Nalgene® bottles and transported

to ATC for analysis.

Liquid levels were marked on the sampling bottles with a marker.

Particulate

analysis

was completed

Analytical

Testing Consultants, Inc., a LELAP

accredited

laboratory

(Certificate

No. 04044) A blank of the acetone reagent was collected

in the field, along with the field samples

and analyzed side by side. According

to standard

practices

and the QA/QC

handbook

EPAo600/4-94- 038c, acetone blanks should not be subtracted

over 0.001%.

The acetone residue of 0.0004 was well under the maximum

allowable

residue of 0.0008.

Corrections

are show in the particulate lab report.

Page 7 of 78PARTICULATE EMISSION

RATE

CALCULATION
LOCA T/ON: Boral Brick SOURCE: Kiln
DATA R #7E

R #8E

AVERAGE DATE 10/17/02

10/17/02 RUN TIME (min)

60.00

45.00 Dn (in)

0.250

0.250 An (ft2)

3.41E-04

3.41E-04 AVG DH (in H20)

1.56

1.51 P ATM (in Hg)

29.64

29.64 Pm (in Hg)

29.75

29.75 Ps (GAUGE)

-0.54

-0.54 Ps (IN HG)

29.60

29.60 Tm (F)

100.13

84.44 Tm (R)

559.80

544.11 Vm (ft3)

41.58

30.17 Vm STD (ft3)

40.33

30.10 VLQ (ml)

34.70

29.00 VV STD (ft3)

1.64

1.37 V STD (ft3)

41.96

31.47 %M 3.90

4.35 4,12 MD 0.961

0.957 MWD 28.94

28.94 M 28.51

28.47 Ts (F)

205.88

"205.89 205.88 Ts (R)

665.55

665.56 665.55 SUM SQRT DP

16.29

12.15. N DP

24.00

18.00 A VG SQRT DP

0.68

0.68 CP 0.84

0.84 Vs (ft/s)

43.29

43.09 43.19 Ds (in)

59.25

59.25 As (ft2)

19.15

19.15 QS, FLOW, ACFM

"49731

-49504 49617 Q STD (ft3/min)

39031

38853 38942 QSTDDRY, FLOWSCFM

37510

"37164 37337 WT(gm) 0.0035

0.0028 %1 100.71

101.16 %C02 1.00

1.00 1.00 %02 19.42

19.51 19.47 %C0 0.00

0.00 %N2 79.58

79.49 PMRc (Ibs/hr)

0.431

0,457 0,444 Cs(GR/SCFD) 0.0013

0.0014 0.0014

Page 10 of 78HCI EMISSION

RATE

CALCULATION
LOCATION; Boral Brick SOURCE: Tunnel Kiln #1
DATA R #7E

R #8E DATE 10/17/02

10/17/02 RUN TIME (min)

60.00

45,00 Dn (in)

0.250

0.250 An (ft2)

3.41 E-04

3,41E-04 A VG DH (in H20)

1.56

1.51 P A TM (in Hg)

29.64

29.64 Pm (in Hg)

29.75

29.75 Ps (GAUGE)

-0.54

-0.54 Ps (IN HG)

29.60

29.60 Tm (F)

100.13

84.44 Tm (R)

559.80

544.11 Vm (ft3)

41.58

30.17 Vm STD (ft3)

40.33

30.10 VLQ (ml)

34.70

29.00 VV STD (ft3)

1.64

1.37 V STD (ft3)

41.96

31.47 %M 3.90

4.35 MD 0.961

0.957 MWD 28.94

28.94 M 28,51

28.47 Ts (F)

205.88

205.89 Ts (R)

665.55

665.56 SUM SQRT DP

16.29

12.15 N DP

24.00

18,00 A VG $QRT DP

0.68

0.68 CP 0.84

0.84 Vs (ft/s)

43.29

43.09 Ds (in)

59.25

59.25 As(ft2) 19.15

19.15 Q$, FLOW, ACFM

49731

49504 Q STD (ft3/min)

39031

38853 Q STD DRY, FLOW $CFM

37510

37164 WT (gin)

2.9100Eo04

4.2200E-04 %1 100.71

101.1 6 %C02 1.00

1.00 %02 19.42

19.51 %C0 0.00

0.00 %N2 79.58

79.49 PMRc (Ibs/hr)

0.036

0.069 Cs (GR/SCFD)

0.00011

0.00022 AVERAGE

4.12

205.88 665.55

43,19
49617 38942 37337
1.00 19.47
0.052 0.00016

Page 12 of 78ISOKINETIC DATA

AND CALCULATIONS
DATE SOURCE R #8E POINT # A1A2A3A4A5A6A7A8A9AIOAllA12B1B2B3B4B5B6 10/17/O2 Kiln

Tm K=

3.311 Ts dp

dH SQRT DP 83 205

0.470

1.56

0.686 84 206

0.410

1.36

0.640 85 206

0.490

1.62

0.700 85 207

0.490

1.62

0.700 87 207

0.480

1.59

0.693 87 208

0.460

1.52

0.678 87 207

0.460

1.52

0.678 86 207

0.450

1.49

0.671 85 206

0.430

1.42

0.656 86 205

0.430

1.42

0.656 85 203

0.440

1.46

0.663 85 202

0.420

1.39

0.648 84 204

0.450

1.49

0.671 83 206

0.460

1.52

0.678 83 206

0.450

1.49

0.671 82 207

0.470

1.56

0.686 82 207

0.480

1.59

0,693 81 207

0.470

,1.56

0.686

%0219.519.619.619.7 19.519,4 19.319.5 19.619.6

% C02

84.44 Vm(ft3) 205.89 Initial

406.39 Final 436.56 Total 30.17

1.51

1•153

1•53 correctedper6C-1 1•51 % N2(BYDIFFERENCE• %Excess A•
Calibration Actual Gas Zero 0.0 Mid-Ranc•e 10.6 Hi-Ranae 19,0

Calibration

Data Instrument Reading Pre- -Post

Pre0.2 0.2 0.95 10.7 10.7

0.48 n/a n/a n/a Based upon 2% of span value (21%) % Error*

1.00 79.49 1327.32

-Post 0.950.48n/a

Page 14 of 78ISOKINETIC SAMPLING

RATE

CALCULATION

dH KdP K (846.72*Dn^4*dH

@*Cp^2*(1-Bw)^2*Md*Tm*Ps)/(Ms*Ts*Pm) R

#7E

R #8E Dn 0.250

0.250 dH@ 1.87

1.87 Y, gamma factor

1.03

1.03 Cp 0.84

0.84 Bw(FRACTION, NOT%)

0.05

0.05 Md 29.00

29.00 Pbar 29.64

29.64 PS (GAUGE)

-0.54

-0.54 Ps 29.60

29.60 Tin, F

100.00

90.00 Tm, R

559.67

549.67 Ms 28.45

28.45 Ts, F

205.00

205.00 Ts, R

664.67

664.67 Pm 29.75

29.75

Page 16 of 78