TUNNEL KILN SCRUBBER and SHAPES KILN EX$AUST 

COMPLIANCE TEST REPORT 

GLEN-GERY CORPORATION 

IBERIA, OHIO 

Testing Date: Apri126, 2006 

Prepared for: 

Mr. Jerry Carrier 

Glen-Gery Corporation 

423 S. Pottsville Pike, Box 340 

Shoemakersville, Pennsylvania 19555 

Prepared by: 

Air/Compliance Consultants, Inc, 

1050 William Pitt Way 

Pittsburgh, Pennsylvania 15238 

412-826-3636 

Project Number: 06-046 

Air/C®mpliance 

C®nsultnnts, inc. 
TUNNEL KILN SCRUBBER and SIIAPES ICILN EXHAUST 

COMPLIANCE TEST REPORT 

GLEN-GERY CORPORATION 

IBERIA, OHIO 

Testing Date: April 26, 2006 

AIR/COMPLIANCE CONSULTANTS, INC. 

(Iv'~xv ~ ~** , /J0— James E. Philhppi 

Senior Project Manager 

~ 

Robert N. Frey 

Vice President 
TABLE OF CONTENTS 

Pap-e 

1 , INTRODUCTION ....................................................................................................................... 1 

1 FIELD PERSONNEL ................................................................................................................. 1 

3, SOURCE DESCRIPTION AND ANY AIR POLLUTION CONTROL DEVICES ................... 1 

4. PLANT PROCESS DATA ......................................................................................................... 2 

5, TEST METHODS SUMMARY ................................................................................................. 2 

5.1, STACK GAS VELOCITY AND VOLUMETRIC FLOW RATE — USEPA 

METHODS1 AND 2 ........................................................................................................ 2 

5.2. OXYGEN AND CARBON DIOXIDE EMISSIONS — USEPA METHOD 3 ................. 3 

5,3. DETERMINATION OF MOISTURE CONTENT IN STACK GASES — USEPA 

METHOD4 ........................................................................................................................ 3 

5.4, PARTICULATE MATTER EMISSIONS — USEPA METHOD 5 ....................................3 

5.5. SLJLFLJR DIOXIDE EMISSIONS — USEPA METHOD 6 ............................................... 3 

5.6, HYDROGEN FLLJORIDE AND HYDROGEN CHLORIDE EMISSIONS — USEPA 

METHOD26A .................................................................................................................. 4 

6. TESTING LOCATION ................................................................................................................ 4 

7, DEVIATIONS FROM THE PROTOCOL ................................................................................. 5 

8 , TESTING RESULTS ................................................................................................................... 5 

9. CONCLUSIONS ........................................................................................................................ 5 

TABLES 

1, PM, HCI, and HF Test Results, Tunnel Kiln Outlet 

2. Sulfiur Dioxide Test Results, Tunnel Kiln Outlet 

3. PM, HCI, and HF Test Results, Shapes Kiln Outlet 

4. Sulfur Dioxide Test Results, Shapes Kiln Outlet 

5, Stack Test Calculations 

APPENDICES 

A. Testing Protocol 

B. Plant Process Data 

C, Field and Computerized Data Sheets 

D. Laboratory Results 

E. Equipment Calibrations 

F. Sample Calculations 

G. Material Balance Data 
TUNNEL KILN SCRUBBER and SFIAPES KILN EXIIAUST 

COMPLIANCE TEST REPORT 

GLEN-GERY CORPORATION 

IBERIA, OIIIO 

1. INTRODUCTION 

Air/Compliance Consultants, Inc. (ACCI) perfonned a compliance testing program for GlenGery Corporation (Glen-Gery) on their Tunnel and Shape Kiln Outlets. Testing was performed 

to demonstrate compliance with Title V renewal testing requirements and Permit to Install (PTI) 

requirements and to establish the site as a synthetic minor hazardous air pollutant (HAP) source. 

Testing was performed for hydrogen fluoride (HF), hydrogen chloride (HCI), sulfur dioxide 

(SOZ), and particulate matter (PM) on the Tunnel and Shapes (also known as Shuttle Kiln) Kiln 

Outlets. A copy of'the testing protocol is located in Appendix A. 

2. FIELD PERSONNEL 

Testing was performed April 26, 2006 by Mr. .Tames Phillippi, Senior Project Scientist; Mr. 

William Cowell, Senior Engineer; Mr. Michael Cowser, Project Scientist; and Mr. Michael 

Matvey, Scientist of ACCI. Mr. Jay Pennwell of the Ohio Environmental Protection Agency 

witnessed a portion of the testing program. Mr. Brett Chronister of Glen-Gery served as a liaison 

for the testing team. 

3. SOURCE DESCRIPTION AND ANY AIR POLLUTION CONTROL DEVICES 

Glen-Gery operates a brick manufacturing plant in Iberia, Marion County, Ohio. This plant 

produces a variety of brick products in both residential and commercial sizes and with a full 

range of product colors, from traditional red brick to gray/white buff-colored brick. 

The Iberia operation uses seven tunnel dryers, one Tunnel Kiln, and one Shapes (Shuttle) Kiln to 

produce the final products. The cars carrying green brick move on tracks through the dryers and 

kilns. Natural gas is the only fuel used to fire the kilns and dryers. The tunnel kiln is equipped 

with a dry limestone adsorber (DLA) to control HF emissions prior to venting to the atmosphere. 
2 

The DLA unit is Hellmich Model No, FKA 594/350-CT. A top-mounted silo stores 

approximately 30 cubic meters of crushed limestone granules. The DLA is comprised of a 

limestone cascade tower with a top mounted limestone feed section. Crushed limestone is 

delivered to the site via truck and distributed to the tower bin pneumatically. The crushed 

limestone trickles vertically from the top mounted storage section and passes through horizontal 

cascades located in the reaction chamber sections of the tower. The DLA is further described in 

the protocol in Appendix A. 

4. PLANT PROCESS DATA 

Glen-Gery personnel recorded the following process parameters during the testing program for 

each kiln exhaust: 

• Kiln througbput (tons frred brick/hour) 

• Type of brick in kiln during testing 

• Pressure drop across the DLA 

• Limestone feed rate 

Plant process data is located in Appendix B. 

5. TEST METHODS SUMMARY 

Testing was conducted following the United States Environmental Protection Agency's 

(USEPA), Title 40, Code of Federal Regulations (CFR), Part 60, Appendix A Testing Methods 1, 

2, 3, 4, 5, 6, and 26A. 

5.1. Stack Gas Velocity and Volumetric Flow Rate — USEPA Methods 1 and 2 

USEPA Method 1 was followed to select sample points across the exhaust stack. The presence 

or absence of cyclonic flow was verified as per USEPA Method 1, Section 11.4 on the exhaust 

stacks. 

i1SEPA Method 2 was followed for the determination of gas velocity and volumetric flow rate. 

This procedure utilized an S-type Pitot tube and inclined manometer to determine stack-gas 

velocity head. Gas temperature measurements were made using a Type K thermocouple and 

49HPROJEC11GIen-Gery &icklW-04616erialCompiience 7eslinBlReportlCompiience Repml Coc 
3 

digital pyrometer. USEPA Method 2 was use'd in conjunction with USEPA Methods 3 and 4 to 

determine the gas velocity and volumetric flow rate at the stack. 

5.2. Oxygen and Carbon Dioxide Emissions — USEPA Method 3 

Carbon dioxide (COz), oxygen (Oz), and stack-gas molecular weight were analyzed and obtained 

in accordance with USEPA Method 3, Fyrite gas analyzers were used in the sampling. Three 

grab samples were taken during each test run. Nitrogen (NZ) was determined by the difference. 

5.3. Determination of Moisture Content in Stack Gases — USEPA Method 4 

The flue gas moisture content at the stack was determined in accordance with USEPA Method 4. 

The gas moisture was determined by quantitatively condensing stack gas in chilled impingers and 

a silica gel absorber. The amount of moishrre condensed was determined by the volume of 

condensate collected in the impingers and silica gel. A dry gas meter was used to measure the 

volume of gas sampled. The amount of water condensed and the volume of gas sampled were 

used to calculate the gas moisture content. Moisture determinations were performed on each test 

run to allow determination of dry stack-gas molecular weight and to calculate the dry standard 

cubic feet per minute (DSCFM) flow rate.. The moisture train sampling was combined with the 

t.TSEPA Method 5/26A, and 6 sampling for each outlet testing location. 

5.4. Particulate Matter Emissions — USEPA Method 5 

PM emissions were determined in accordance with USEPA Method 5. A sample was drawn 

isokinetically from the gas stream and collected in a glass nozzle, probe, and on a heated, tared 

Teflon or quartz filter. A series of glass impingers were used to collect moisture. A calibrated 

dry gas meter measured the gas sample volume which was at least 36 dry standard cubic feet 

(DSCF). Sample recovery procedures followed USEPA Method 5 guidelines and samples were 

analyzed by ACCI, This sampling train was combined with the USEPA Method 26A sampling 

train. 

5.5. Sulfur Dioxide Emissions — USEPA Method 6 

SOZ emissions were determined in accordance with USEPA Method 6. A sample was drawn 

from a single point in the gas stream at a constant rate and collected in a glass probe, and in a 

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series of glass impingers. The first impinger contained 80% isopropyl alcohol (IPA), and 

impingers 2 and 3 contained 3% hydrogen peroxide (HZOz). A 47 mm filter was inserted 

between impingers 1 and 2. A calibrated dry gas meter measured the gas sample volume which 

was at least 36 DSCF. Sample recovery procedures followed USEPA Method 6 guidelines and 

samples were analyzed using Ion Chromatography (IC) by Air Quality Services. 

5.6. Hydrogen Fluoride and Hydrogen Chloride Emissions — USEPA Method 26A 

HF and HCl emissions were determined in accordance with USEPA Method 26A. A sample was 

withdrawn isokinetically from the gas stream and collected in a glass nozzle, probe, and on a 

heated, tared Teflon or quartz filter. The filter was connected to a series of four full-sized 

impingers. The first two impingers contained O.IN sulfuric acid the third impinger was empty 

and the fourth impinger contained a known quantity of silica gel. 

The impingers and connecting glassware were rinsed three times with deionized water which was 

combined with the impinger catch. The HF and HCI samples were analyzed by Ion 

Chromatography by Air Quality Services. 

6. TESTING LOCATION 

The Tunnel Kiln Scrubber exhausts through a 130' high stack. Two 90° opposed sampling ports are 

located at a point meeting at least the minimum USEPA Method 1 criteria with the nearest 

upstream disturbance being a minimum of one-half diameter and the nearest downstream 

disturbance being at least 2 diameters away (Figure 5 of the Test Protocol, Appendix A). Twelve 

traverse points (6 per port) were utilized to establish gas flow rate for the 48" diameter exhaust 

stack. 

The Shapes Kiln exhausts through a 25" duct which enters the tunnel Kiln scrubber exhaust aRer 

the control device (Figure 1 of the Test Protocol, Appendix A). Twent,y-four traverse points (12 per 

port) were utilized to establish gas flow rate for the 27" diameter exhaust stack (Figure 6 of the Test 

Protocol, Appendix A). 

Z:W.PROIECTGIonrvGery 8rick106-0461berialCOmplianco TuslinB~ ReportlCompllenw Report tloc 
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7. DEVIATIONS FROM THE PROTOCOL 

Testing on the Tunnel Kiln Irilet was not completed because the sample port was inaccessible due 

to lack of clearance with the ceilir,g above the top test port. Sampling was attempted, but the 

leak check failed because the heated line from the end of the probe to the filter box became loose 

during testing due to the ceiling obstruction. The use of a single test port, reducing the number 

of sampling points, or altemate methodologies, was not approved by the OEPA. Therefore, 

process samples were collected and material balance calculations were performed to determine 

the inlet loading and system removal efficiency. 

El Y 0&1111`r!7 19 *10 * K`7 

Tables 1 and 2 contain the PM, HCI, HF, and SOz testing results for the tunnel kiln exhaust, 

respectively. The Shapes Kiln exhaust PM, HCI, HF, and SOZ testing results are contained in 

Tables 3 and 4, respectively. Table 5 presents a summary of the material balance calculations. 

Field and computerized data sheets are contained in Appendix C. Laboratory data and equipment 

calibrations are contained in Appendices D and E, respectively. Sample calculations for each 

USEPA testing method for each testing location are contained in Appendix F. Supporting 

process data for the tunnel kiln material balances and Shapes Kiln emission estimates is included 

as Appendix O. 

9. CONCLUSIONS 

A compliance testing program was performed Apri126, 2006 for the Glen-Gery Corporation at their 

Iberia, Ohio facility. Testing was performed on the Tunnel and Shapes Kiln outlets for particulate 

matter, hydrogen fluoride, hydrogen chloride, and sulfur dioxide. Testing was performed to 

demonstrate compliance with Title V renewal testing requirements and Permit to Install (PTI) 

requirements and to establish the site as a synthetic minor hazardous air pollutant (HAP) source. 

Za4PROJECT1GIemGery Brick\B6 ~ 0461barielCompliance TestlnBARepotllCompllence Report.doe 
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Table I PM, HCI, and HF Test Results, Tunnel Kiln Outlet 

G1en Gery Corporation, lberia Plant, Iberia, Ohio 

Test Parameters Run 1 Run 2 Run 3 Average 

Date 26-Apr-06 26-Apr-06 26-Apr-06 

Start Time 10:00 AM 12:53 PM 3:00 PM 

End Time 11:17 AM 1:56 PM 4:02 PM 

Flow Rate (ACFM) 35,889 38,439 37,489 37,273 

Flow Rate (SCFM) 20,896 22,340 21,877 21,704 

Flow Rate (DSCFM) 19,114 20,311 19,750 19,725 

Sample Volume (DSCF) 39.947 41 190 40.212 40.450 

Carbon Dioxide (CO,) (dry volume %) 6.00 600 6.00 6.00 

Oxygen (OZ ) (dry volume %) 14.00 1400 14, 00 1400 

Water Vapor (H20) (volume %) 8,53 908 9,72 9.11 

StackTempemture (°F) 4161 416.2 411.1 414A 

Percent of Isokinetic Sampling (%) 102.42 99.39 99.78 100.5 

Results 

Particulate Matter (PM) 

Mass Collected (mg) 16.33 2543 37.10 2628 

Emission Concentration (gr/DSCF) 0 006 0.010 0.014 0.010 

Emission Rate (lb/hr) L 03 1.66 241 1 70 

Emission Rate 1 (ton/yr) 453 7,26 1055 7.45 

Hydrogen Chlor7de (HCI) 

Emission Mass (mg) 14.70 12.90 11.90 13.17 

EmissionRate (Ib/hr) 0.93 0.84 0,77 0,85 

Emission Rate 1 (ton/yr) 408 3,69 3,39 3 72 

Hydrofluoric Acid (HF) 

Emission Mass (mg) 8.20 8.40 8.70 8.43 

Emission Rate (lb/hr) 0.57 0,60 0.63 0.60 

Emission Rate t (ton/yr) 2,49 264 2.74 2.62 

Ton per year calculations are based on 8,760 hours of operation 

ACFM Actual cubic feet per minute 

SCFM Standard cubic feet per minute 

DSCFM Dry standard cubic feet per minute 

DSCF Dry standard cubic feet 

°F Degrees Fahrenheit 

Ib/hr Pounds per Hour 

gr/DSCF Grains per dry standard cubic feet 

mg Milligrams 

% Percent 

Za4PROdECT1GIen-GCry Br1ck106-046 Iberia\Compliance Testing\Tunnel Kiln Outiel\Methotl 526A Tunnel Kiln Outlet Iberia. Summary 5/1912006 
Table 2. Sulfur Dioxide Test Results, Tunnel Kiln Outlet 

Glen Gery Corpomtion, Iberia Plant, iberia, Ohio 

Test Purnmeters Run I Run 2 Run 3 Average 

Date 26-Apr-06 26-Aprrv06 26-Apr-06 

Start Time 10:00 AM 12:53 PM 3:00 PM 

End Time 11:00 AM 1:53 PM 4:00 PM 

Flow Rate (ACFM) 35,889 38,439 37,489 37,273 

Flow Rate (SCFM) 20,893 22,375 21,949 21,739 

Flow Rate (DSCFM) 20,261 20,743 20,281 20,428 

SampleVolume (DSCF) 41.412 42445 41.400 41752 

Carbon Dioxide (CO,) (dry volume %) 6.00 6.00 6.00 6.00 

Oxygen (O,) (dry volume %) 14.00 1400 14.00 1400 

Water Vapor (H2O) (volume %) 3.03 729 7.60 5.97 

Stack Temperature ("F) 41608 416.17 41108 414.44 

Results 

Sulfur Dioxide (SOy) Results 

Mass Collected (mg) 4732 508,0 421.0 4674 

Emission Rate (Ib/hr) 30.62 3284 2728 30.25 

Emission Rate (ton/yr) 134.1 143.8 119.5 132.5 

' Tons per year calculations based on 8,760 hours of operation 

% Percent 

ACFM Actual cubic feet per minute 

SCFM Standard cubic feet per minute 

DSCFM Dry standard cubic feet per minute 

DSCF Dry standard cubic feet 

°F Degrees Fahrenheit 

Ib/hr Pounds per hour 

mg Milligrams 

ZIWPROJECT\Glen-Getyatick\66-e461bena\CompliancnTesling\TunnelKilnON@WdelhodBTUnneIKIInOWeL Snmmary 51192oo4 
Table 3. PM, HCI, and HF Test Results, Shapes Kiln Outlet 

Glen Gery Corporation, Iberia Plant, Iberia, Ohio 

Test Parameters Run 1 Run 2 Run :3 Average 

Date 4/26/2006 4/26/2006 4/26/2006 

Start Time ] 0:00 AM 12:53 PM 3:00 PM 

E.nd Time 11:47 AM 1:56 PM 4:02 PM 

Flow Rate (ACFM) 5,885 5,387 5,480 5,584 

FlowRate (SCFM) 4,469 3,982 4,025 4,159 

F1owRate (DSCFM) 4,453 3,903 3,989 4,115 

SampleVolume (DSCF) 47.195 43344 43.280 44606 

Carbon Dioxide (COZ ) (dry volume %) 0.00 0.00 0,00 000 

Oxygen (O,) (dry volume %) 21,00 21,00 21,00 21.00 

Water Vapor (H 2 0) (volume %) 0.35 1.99 0.87 1.07 

Stack Temperature (°F) 2180 2366 239.8 231.5 

Percent of Isokinetic Sampling (%) 96.70 101.35 9900 99.0 

Results 

Particulate Matter (PM) 

Mass Collected (mg) 4,86 8 16 7.39 6.80 

Emission Concentration (gr/DSCF) 0.002 0 003 0 003 0 002 

Emission Rate (Ib/hr) 11061 0 097 0 090 0,083 

Hydrogen Chloride (HCl) 

Emission Mass (mg) 6,90 340 2.10 4.13 

Emission Rate (lb/hr) 009 004 003 005 

Hydrofluoric Acid (HF) 

Emission Mass (mg) 21 40 30.90 1880 20.10 

E.mission Rate (lb/hr) 0.27 038 0.23 0.29 

ACFM Actual cubic feet per minute 

SCFM Standard cubic feet per minute 

DSCFM Dry standard cubic feet per minute 

DSCF Dry standard cubic feet 

°F Degrees Fahrenheit 

Ib/hr Pounds per I-tour 

gr/DSCF Graitis per dty standard cubic feet 

mg Milligrams 

% Percent 

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Table 4 Sulfur Dioxide Test Results, Shapes Kiln Outlet 

Glen Gery Corporation, Iberia Plant, Iberia, Ohio 

Test Parameters Run I Run 2 Run 3 Average 

Date 26-Apr-06 26-Apr-06 26-Apr-06 

Start Time ] 0:02 AM 12:54 PM 3:02 PM 

End Time 11:02 AM 1:54 PM 4:02 PM 

Flow Rate (ACFM) 5,885 5,387 5,480 5,584 

FlowRate (SCFM) 4,480 3,987 4,022 4,163 

Flow Rate (DSCFM) 4,387 3,901 3,979 4,089 

Sample Volume (DSCF) 42 568 42,099 41 761 42 143 

Carbon Dioxide (CO,) (dry volume %) 000 000 000 000 

Oxygen (O,) (dry volume %) 21 ,00 21 .00 21 ,00 21.00 

Water Vapor (H 2 0) (volume %) 2.08 2.16 1,07 1 77 

StackTemperature (°F) 21633 235.75 24033 230.81 

Results 

Sulfur Dioxide (SOZ) Results 

MassCollected (mg) 43,1 106.9 523 67,4 

Emission Rate (1b/hr) 0.59 1 31 066 0.85 

% Percent 

ACFM Actual cubic feet per minute 

SCFM Standard cubic feet per minute 

DSCFM Dry standard cubic feet per minute 

DSCF Dry standard cubic feet 

°F Degrees Fahrenheit 

1b/hr Pounds per hour 

mg Milligrams 

ZY+PROIECTGIen-Gery Brick106-e46 Ibena\Compliance Testing\Shapes Kiln OutletWethod 8 Shapes Kiln Outlet. Summary 6~J20U6 
Table 5. Stack Test Calculations, Apri126, 2006 

rlen Gery Iberia, Ohio 

Tunnel Kiln Process Data 

Push Rate 

# Bricks per Car 

Weight of 1 Brick 

Process Rate 

Process Rate 

Mass Balance Results 

Car Number MB 1-59 

Car Number MB 8-59 

Car Number MB 15-59 

Average 

Inlet Emissions Rate 

Cars/day 23 

Bricks/Car 9,360 

Ib 3.8 

lb Brick/hr 34,086 

tons Brick/hr 17.04 

HF HCI SOZ 

]b HF / ton fired clay 0.22 0.07 1,905 

lb HF / ton fired clay 0.36 0.03 2.011 

lb HF / ton fired clay 0.24 0.11 1,799 

lb HF / ton fired clay 0.27 0-07 1,91 

Ib HF/hr 4.66 1-19 32,47 

Stack Test Results 

Tunnel Kiln (includes Shapes) lb HF /hr 0.6 0.85 29.93 

Shapes Kiln Ib HF /hr 030 0.05 0,084 

Outlet Emissions Rate ]b HF /hr 0.30 0.80 29,85 

Control Efficiency % 93,6 32.9 N 

Z:\APROJECIIGIen-Gery Brick\06-046lberia\Comptiance Testing\Shapes Kiln Outlet\Method 8 Shapes Kiln Outlet Table 5 612/2006 
APPENDIX A 

' ~; ;•: ~ ~ 'f; 
TUNNEL KILN SCRUSBER and S)EIAPES KILN E1{T3AUST 

COMPLIANCE TEST PROTOCOL 

GLEN-GERY CORPORATION 

IBERIA, OHIO 

March 2006 

Prepared for: 

Mr. .lerry Carrier 

Glen-Gery Corporation 

423 S. Pottsville Pike, Box 340 

Shoemakersville, Pennsylvania 19555 

Prepared by: 

Air/Compliance Consultants, Inc. 

1050 William Pitt Way 

Pittsburgh,Pennsylvania 15238 

412-826-3636 

Project Nmnber: 06-046 

r' 

1 I l i 
TUNNEL I(H,N SCRTJSBER and SIiAPES IOLN EXHATJST 

COMPLIANCE TEST PROTOCOI, 

GLEN-GERY CORPORATION 

M ia blS 

ffu~~_ ... 11 ? 

A.IR/CON1P'L7ANCE CONSULTtlNTS, IIVC. 

J afvv az~ Tak.0 9-v - ~' 

James E. Phillippi ~ 

Senioi Project Manager 

10/ 

Robert N. Frey 

Vice President 
TABLE OF CONTENTS 

Paae 

I COMPANY AND TESTING FIRM INFORMATION.... ........__ . ..... ._ 

2. TESTING LOCATION .. .......... . _,. ..... _ _.. . i 

3 ANALYTICAL LABORATORY INFORMATION-.. .. ..... .._ - _ . .. ..........._ , . .... .1 

4. RELEVANT OEPA CORRESPONDENCE.._ .... . ... ......... .:. .:....... ... ......... ...__ 2 

5 OBTECTIVES OF TESTING PROGRAM.... - _ _ . .. .. _. . ._. _ _.. ..-...... _ .. _., ,2 

6 SOURCE DESCRIPTION AND ANY AIR POLLUTION CONTROL DEVICES --.2 

7 SIMPLE BLOCK. DIAGRAM .... _ _ ..... .. .. . ........ _ .. . ., _ _.. 3 

8. PROCESS OPERATING CONDiTIONS _ _.. . _ . 3 

9 PROCESS PARAMETERS. ._ _ , ... .. __._ . . . . . . _.._... . ... _ . ... .. . . .. ...- .3 

10 TEST METHODS SUMMARY. __ - _ _. . _ _._. .. . . . ........ . . 4 

11. SAMPLE COLLHCTION AND RECOVERY..... .._-.. ._ __..,_. .... ....:..__ ................. 4 

11 TESTING LOCATION .. ._ _...._6 

13 SAMPLE HANDLING PROCEDURES . _ , .. _.__.. .. . _.., _ ... . . ._ _ ... 7 

14 FORMULAS TO BE USED IN DATA REDUCTION ...... .. .. ..... . ...._... .... _ . - .,. 7 

15, EXAMPLES OF FIELD DATA SHEETS , .. . . ....... ..,. . .. ... . . _.. _... ._..__ _. . .7 

16. TESTINGSCHEDULE- _.. ._ __......_ ._...... .... ...8 

17. REPORTING . . .. __... . _.- .. ..... _ . ... . . 8 

FIGUI2ES 

1. Process Flow Diagram 

2 USEPA MeUiod 5/26A Sampling Tiain Schematic 

3, USEPA Metbod 6 Sampling Train Schematic 

4.. Tunnel Kiln Scrubber Inlet Sampling Port Diagrarn 

5 Tunnel ICiln Scrubber Outlet Sanipling Port Diagram 

6 Sbapes Kiln Exhaust Duct Diagram 

APPENDICES 

A OEPA Intent to Test Fonns 

B Sample Calculations 

C- Sainple Data Sheets 
TUNNEL IQLN SCRUBBER and SIIAPES IOLN EXI3AUST 

COMPLIANCE TEST PROTOCOL 

GLEN-GERY CORPORATION 

IBERIA, OHIO 

1. COMPANY AND TESTING FIRM INFORMATION 

COMPANY CONTACT TESTING CONTACT 

Mr. Teny Carrier 

Glen-Gery Corporation 

423 S. Pottsville Pilce 

Shoemalcersville, Pennsylvania 

(610) 698-4627 — Telephone 

(610) 562-2084 — Facsimile 

jcarTier@gle.ngerybricic.com 

Mr. James E Phillippi 

Air/Compliance Consultants, Inc. 

1050 William Pitt Way 

19555 Pittsburgh,Pennsylvania 15238 

(412) 826-3636 — Telephone 

(412) 826-3640 — Facsimile 

jphill@air-comp com 

2. TESTING LOCATION 

Glen-Gery Corporation 

Iberia Plant 

P O. Box 207 — County Line Rd_ 9 

Iberia, Oliio 43325-0208 

(419) 468-5002 - Telephone 

3. ANALYTICAL LABORATORY INFORMATION 

Hydrogen fluoiide (HF) and hydrogen chloride (HCl) analysis wi11 be completed by: 

Ms NancyM Kotsko 

Air Quality $ervices 

4527 Clairton Blvd 

Pittsburgh, PA 15236 

(412) 881-5630 — Telephone 

PA Laboratory Registration No, 02-711 

Particulate matter (PM) analysis will be completed by: 

Mr James E Phillippi 

Air Compliance Consultants, Inc. 

1050 William Pitt Way 

Pittsburgh,PA 15238 

(412) 826-3636 — Telephone 

PA Laboratory Registration No. 02-742 
2 

4. RELEVANT OEPA CORRESPONDENCE 

Appendix A contains the Intent to Test forms for tlre Ohio Environmental Protection Agency 

(OEPA). 

5. OBJECTIVES OF TESTING PROGRAM 

Testing is being conducted to determine compliance witli I-IF, PM, and sulfur dioxide (SOz) 

emission limits and removal efficiency forHF as described below: 

_ Tunnel I{iln (P008) Shapes Kiln (POI1) 

Pollutaut Inlet to Scrubbert' 1 Outlet from Scrubber(') In duct prior to stacict' 1 

HF Title V and PTI PTI PTI & Title V 

HCl PTI PTI 

SOZ Title V Titie V 

PM Title V Title V 

PTI - Pernzit to hrstall 

Notes: 

t ])Emissions from the Tunnel I{iln (P008) measured prior to mixing with emissions from the 

Shapes Kiln. 

(Z)Emissions from the Shapes I<iln (P011) measured prior to mixing with emissions fiom the 

Tunnel Kiln 

Testing is being completed to establisli the site as a syntlietic minor hazardous air pollutant 

(I-IAP) source, to meet PTI requirements, and to meet Title V renewal testing requirements 

6. SOURCE DESCRIPTION AND ANY AIR POLLUTION CONTROL DEVICES 

Glen-Gery Corporation (Glen-Gery) owns and operates a bricic manufacturing plant in Marion 

County, Ohio. This plant produces a variety of brick products in both residential and commercial 

sizes and with a full range of product colors, from traditional red bricic to gray/wlrite buff-colored 

bricic 

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The Iberia operation uses seven tunnel dryers, one tunnel kiln, and one shuttle kiln to produce the 

final products. The cars can-ying green brick move on tracks tluough the dryers and I<ilns, 

Natural gas is the only fuel used to fire the kilns and dryers. The tunnel kiln is equipped with a 

dry limestone adsorber (DLA) to control HF emissions prior to venting to the atmospliere 

The DLA unit is Hellmich Model No FICA 594/350-CT- A top-mounted silo stores 

approximately 30 cubic meters of crushed limestone granules. The DLA is comprised of a 

limestone cascade tower with a top mounted limestone feed section. Crushed limestone will be 

delivered to the site via truck and distributed to the tower bin pneumatically. The crushed 

limestone will trickle vertically from the top mounted storage section and pass through horizontal 

cascades located in the reaction chamber sections of the tower, The DLA is fnrther descr'ibed in 

the corresponding 2006 Permit-To-Install (PTI) establishing synthetic minor HAP limits for the 

plant. 

7. SIMPLE BLOCK DIAGRAM 

Figrue I provides a simple block diagram8: PROCESS OPERATING CONDITIONS 

Testing will take place during periods of maximum production. 

9. PROCESS PARAMETERS 

Glen-Gery personnel will be responsible for recording the following process parameters during 

the testing period: 

• IGIn 8uoughput (tons frred brick/hour); 

• Type of brick in lciln during testing; 

• Pressure drop across the DLA; and 

• Limestone feed rate. 

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10. TEST METHODS SUMMARY 

1'esting will be conducted following the United States Environmental Protection Agency's 

(USL•PA), Title 40, Code of Federal Regulations (CFR), Part 60, Appendix A Testing Methods.. 

The following is a summary table listing testing methods for the program: 

USEPA Method 1 "Sample and Velocity Traverses for Stationary Sources" 

USEPA Method 2 "Determination of Stacic Gas Velocity and Volumetric Flow Rate 

(Type S Pitot Tube)" 

USEPA Metliod 3 "Gas Analysis for Carbon Dioxide, Oxygen, Excess Air, and Dry 

Moleeular Weight" 

USEPA Method 4 "Determination ofMoisture Content in Stacic Gasses" 

USEPA Method 5 "Determination of Particulate Matter from Stationary Sources" 

i7SEPA Method 6 "Determination of Sulfur Dioxide Emissions from Stationary 

Sources" 

USEPA Method 26A "Determination of Hydrogen Halide and Halogen Emissions from 

Stationary. Sources, lsokinetic Method" 

11. SAMPLE COLLECTION AND RECOVERY 

11.1. Traverse Point Selection — USEPA Method 1 

USEPA Method 1 will be followed for the determinations of traverse point selection 

11.2. Stacic Gas Velocity and Volumetric Flow Rate — USEPA Method 2 

USEPA Metliod 2 will be followed for the detennination of gas velocity and volumetric flow 

rate. This procedure utilizes an S-type Pitot tube and inclined manometer to determine stacic-gas 

velocity head. Gas temperature measurements will be made using a Type K thermocouple and 

digital pyrometer. 

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11.3. Oxygen and Carbon Dioxide Emissions — USEPA Metbod 3 

Carbon dioxide (COZ), oxygen (02), and stacic-gas molecular weiglit will be analyzed and 

obtained in accordance with USEPA Method 3. Fyrite gas analyzers will be used in the 

sampling Three grab samples will be talcen during each test run. Nitrogen (Nz) will be 

detemuned by the difference. 

11,4. Determination of Moisture Content in Stacic Gases — USEPA Method 4 

The flue gas moisture eontent at the stacic will be determined in aecordance with USEPA 

Method 4 The gas moisture will be determined by quantitatively condensing stacic gas in chilled 

impingers and a silica gel absorber The amount of moisture condensed will be deternuned by 

the volume of condensate collected in the impingers and silica gel. A dry gas meter will be used 

to measure the volume of gas sampled The amount of water condensed and the volume of gas 

sampled will be used to calculate the gas nioisture content Moisture determination will be 

performed on each test run to allow determination of dry stacic-gas molecular weight and to 

calculate the dry standar'd cubic feet per minute (DSCFM) flow rate The moistur'e train 

sampling will be combined with the iJSEPA Method 5/26A, and 6 sampling. 

11.5. Particulate Matter Emissions — USEPA Method 5 

PM emissions wi11 be detemiined in accordance witlr USEPA Method 5.. A sample will be drawn 

isolcinetically from the gas stream and collected in a glass nozzle, probe, and on a heated, tared 

Teflon or quartz flter A series of glass impingers will be used to collect moisture. A calibrated 

dry gas meter will measure the gas sample volume which will be at least 36 dry standard cubic 

feet (DSCF) Sample recovery procedures will follow USEPA Metlrod 5 guidelines and samples 

will be analyzed by ACCI_ This sampling train will be combined with the USEPA Method 26A 

sampling train.. Figure 2 eontains a diagram of the USEPA Metliod 5/26A train. 

11.6. Sulfur Dioxide Emissions — USEPA Method 6 

S02 emissions will be determined in accordance witli USEPA Method 6 A sample will be 

dr'awn fronr a single point in the gas stream at a constant rate of approximately 0 75 cubic feet 

per mir7ute (CFM), and collected in a glass probe, and in a series of glass impingers. The first 

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impinger will contain 80% isopropyl alcohol (IPA), and impingers 2 and 3 will contain 3% 

hydrogen peroxide (HzOZ). A glass wool plug or equivalent will be inserted between impingers 1 

and 2. A calibrated dry gas ineter will measure the gas sample volume wlriclr will be at least .36 

DSCF Sample recovery procedures will follow USEPA Method 6 guidelines and samples wi11 

be analyzed using Ion Cliromatography (IC) by Air Quality Services., Figure 3 is a Method 6 

sarnpling train schematic 

11.7. Hydrogen Fluoride and Hydrogen Chloride Emissions - USEPA 1Vlethod 26A 

I-]F and HCl eniissions will be detennined in accordance with USEPA Method 26A A san<ple 

will be withdrawn isolcinetically from the gas stream and collected in a glass nozzle, probe, and 

on a heated, tared Teflon or quartz filter. The filter will be connected to a series of four full sized 

impingers. The first two impingers will contain O IN sulfuric acid the third impinger will be 

empty and the fourtlr impinger will contain a Icnown quantity of silica gel. 

The impingers and connecting glassware will be rinsed three times with deionized water which 

will be combined with the impinger catch. The HF and HCI samples will be analyzed by Ion 

Cliromatography by Air Quality Serviees 

12, TESTING LOCATION 

The Tunnel IGIn Scntbber inlet testing location contains two 90° opposed sampling ports The inlet 

duct is 48" in diameter and the nearest downstream disturbance is approximately 025 diameters 

away, and the nearest upstream disturbance is approximately 175 diameters away These test ports 

do not ineet the required dimensions in USEPA Method l Cyclonic flow checics will be made 

prior to testing and the maximum of twenty-forir tiaverse points (12 per diameter) will be u6lized 

on the scmbber inlet testing location Figure 4 shows a diagram of the Tunnel ICiln Scrubber Inlet 

sampling ports. 

The Twmel ICiln Scrubber exhausts tlirough a 130' stacl< Two 90° opposed sainpling ports are 

located at a point meeting at least the minimum USEPA Method I criteria witl7 the nearest 

upstream dislurbance being a minimum of one-half diameter and the nearest downstream 

disthtrbance being at least 2 diaineters away.. It is assuined that 12 traverse points (6 per port) will 

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be utilized to establish gas flow rate for the 48" diameter exhaust stacic Figure 5 shows a diagram 

of the Tunnel ICiln Outlet sampling ports. 

The Sliapes ICiln exhausts through a 25" duct which enters the tunnel Kiln scrubber exliaust after 

the control device. Figure 6 shows a diagram of the Shapes ICiln Exlraust. 

All dimensions will be verified in the field and sampling points selected according to USEPA 

Method I . 

Sample Point Information: 

USEPA Points Minutes Total 

Location Constituent Method Per Port Per Point Minutes 

(minimum) 

Tunnel Kiln I-IF PM, S02 1-5, 6, 26A 6 2.5 60 

Scrubber Outlet 

Tunnel ICiln HCI, HF 1-4, 26A 12 2.5 60 

ScrubberInlet 

Shapes ICiln BF, S02 1-5, 6, 26A 6 2.5 60 Hi 

1.3. SAMPLE HANDLING PILOC);DURES 

All sample recovery and handling procedures will follow the respective USEPA Method 

guidelines Chain of Custody Forms will be completed and accompany samples to the 

laboratory 

14. FORMULAS TO BE USED IN DATA REDUCTION 

See Appendix B. 

15. EXAMPLES OF FIELD DATA SHEETS 

See Appendix C 

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16. TESTING SCHEDIJLR 

Testing has tentatively been scheduled for March 2006.. Testing will be scheduled in accordance 

with the construction petmit. The OEPA is being notified a minimum of 30 days prior to the 

testing date. 

17. REPORTING 

At the conclusion of the compliance testing program, a test report summarizing the findings of ihe 

emission test program will be prepared in accordance with USEPA and OEPA requirements 

Included in the report will be a sampling procedure description, individuals present during the test 

program, removal efficiency for I3P, and emission rates for HF, HCI, PM, and S02 from both the 

tumiel lciln (P008) and shuttle kiln (P011) . The report will also contain all field data sheets, 

calibration slieets, laboratory analysis, and supporting sample calculations The final report will be 

submitted within 45 days after the testing is completed. 

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iHE FOLLOWINO ADDITIONAL INFOflMAT10N SHAL L. BE SUBMITTED AS ATRACIiMENTS: 

F Samplc Train lnformation: 

I A schcmatic diagram ot each sampling train 

2 The type or lypes of capture media to be used lo collect each gas slremn pollmonl ( Include frller specificalion shects) 

3 Sample lubc lype. (c g., glass, icflon. stainless stcel, cic ) 

4 Probe cleaning mclhod and solvent lo bc used, if applicable 

G LoboratoryAnulysis 

A descriplion of the laborntory nnulysis methods lo be used lo dclermine the wncenbation of cach pollutnnt 

H DcAcriplion of Operalion: 

A descriplion of ony opemlion, process or activily Ihat could vcnt exlraust gases to the Icsl slack This shall includc lhc 

descriplion and fecd rnte of nll materinis capable of pradueing pollutnnl emissions used in eoch seporale operptfon 

Notc 1: All Iesting shnil be performed al maximum rnle caPoeity ns specified by thc equipment manufaclurer or at the maximum 

rnte actully used in lhe emissions unil operation, whichever is grcater. or at any rate speciGed by the ndminisuator 

Notc 2: If the emissions unit is nnt operated at maximum cnpacily, or as close as possible Ihercto, lhc cmissions unit might 

bc dcralcd to lhot productinn copacily 

Notc 3: Produclion rccords nnd pammctric monitoring rccords must bc includcd in Oro fnal rcport 

Stnck nnd Vent Descriplion: 

A dimensional skcich or sketches showing thc plan and elevalion view of'the entire ducting and stack armngcmcnl The sketch 

should include thc rclative position of nl) processed or operations vcnling to the stack or vent to be tesled It should also includc 

Iltc posilion of ihe porls rclativc to thc ncnresl upsucam and downstrcam gas (low dislurbancc or ducl dimcnsional c6angc Thc 

skciches sllould include thc rclalive position.. type, and manufacturets clalmcd cfGciency of all gns cicnning equipment 

A cross scctional dimcnsional skctch of lhc stack or duct al the sampling pons. showing Ihc posilion of sampling points In 

case of a rectangulor ducl. shove division of ducl into equal nreas 

Safety: 

Describc all possible safety hulnrds ineluding such items as Ihe presence ofioxic fumes high noise Ievcls, mes where eyc 

prolcclfon is required. etc Noto: Conditions considered unsnfe n1 thc lime of Ihe test ivill cause postponemerrl 

Test Rcpon: 

The final test rcpon must contain, ns a minimum. Ihc following infonnatinn to be ncecpmble: 

All mw dala shccts. including slrip charts wbure npplicnblc 

Proccss dnm 

Rcsulls of audit samplcs 

Alllab analyses dnta 

All calibmtion datn 

Complcic chain-of-custody rccords for all samplcs rcmovcd from !he fzcility for recovcry and/or nnalysis 

All formulas used in calculating emission rntes if difrerent Ihnn specifred in the npplicable reference medrod 

An cxpinnalion of nll dismptions encountered during Ihe Icsl period. (i c. Meler box changes, process shntdowns. 

brokcn glasswarc. ctc ) 

Backholf anulysis if dcicrmining porticalatc cmissions thal arc 10 microns in aerodynamic diamcicr or Icss 

Notc: In accordancc wilh OAC 3745-15-04 Ihe mpon must bc submittcd within 30 days of conducting thc tcst 

L Test Postponcmcnt 

It is underslnndable ihnl a test tvill necd lo be postponed duc lo circumslances tbnt would not ollow representotive eondilions 

to bc e5tablishcd such ns recent maintcnance or modihcolion, equipmeni failure. or lhc absence of key personncl flowever. 

concern thal n Icst will result in a dctcnninotion of non-compliancc is not n valid renson for puslponcmcnt nnd n f:rcility 

dccision to posrpone wilhout a vnlid renson may result in enforcement action xgninst the facility 

OAIn F.P.I fnrm nArn7 

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