Pollution Control System Evaluation and Source Emissions Testing 

Boral Brick 

Terre Haute, Indiana 

Initial Emissions Testing 

DIFF Inlet- PM, HCI/HF and SO2 

DIFF Outlet- PM/PMlo w/HCI / HF, and SO2. 

Clay Prep St•;k- •v•, PMlo and VE's 

August 19 and 20, 2008 

Entec Project No.: 28162 

16-D Commerce Avenue Hueytown, Alabama 35023 Phone: (205) 491-6676 Fax (205) 491-6614 

www. entecs ervices, com 
Entec Services, Inc. 

16-D Commerce Avenue 

Hueytown, Alabama 35023 

Telephone: (205) 491-6676 

Fax: (205) 491-6614 

Results of the August 19 and 20, 2008 

Initial Emissions Testing on the 

DIFF Inlet, the DIFF Outlet Stacks and the 

Clay Preparation Dust Collector Stack at the 

Boral Brick facility located in 

Terre Haute, Indiana 

Permit No. T167-23205-00139 

Submitted to: 

Boral Brick Company 

P.O. Box 1178 

Columbus, Georgia 31902 

Attention: Ms. May Ann Keon 

Entec Project No. 28162 

Completed By: 

Art Otero 

Project Leader 

Report Submitted September 10, 2008 

Reviewed By: 

Tom Lotz. 

Technical Services Manager 

hereby certify to the best of my knowledge all field sampling and laboratory analysis performed for 

this report is authentic and accurate. It has been checked for completeness and accuracy. 
Boral Brick Company 

Section 

Table of Contents 

Page No. 

Executive Summary 

Emissions Summary 

Detailed Test Results 

Sampling Procedures 

Location of Test Ports 

Method 6C Sampling Train 

Method 5 / 26A Sampling Train 

Field Data Sheets DIFF Baghouse Inlet- 26A 

Test Run 1 

Test Run 2 

Test Run 3 

Field Data Sheets DIFF Baghouse Inlet PM 

Test Run 1 

Test Run 2 

Test Run 3 

Field Data Sheets DIFF Baghouse Outlet 26A 

Test Run 1 

Test Run 2 

Test Run 3 

Field Data Sheets DIFF Baghouse Outlet- PM 

Test Run 1 

Test Run 2 

Test Run 3 

Field Data Sheets Clay Prep Dust Collector Stack 

Test Run 1 

Test Run 2 

Test Run 3 

Field Data Sheets Clay Prep Building Method 22 

Field Data Sheets Primary Crusher Bldg Method 22 

Control Room Production Data 

Quality Control / Quality Assurance Procedures 

1 

2 

7 

23 

33 

37 

38 

39 

40 

47 

53 

59 

60 

64 

67 

70 

71 

78 

84 

90 

91 

95 

98 

10t 

102 

107 

111 

115 

116 

117 

121 
Field QA/QC Checklist 129 

Meter Orifice Check and Temperature Check 132 

Fyrite / Orsat Standardization 136 

Preliminary Traverse and Cyclonic Flow Verification 142 

Traverse Point Location Sheet 146 

Method 6C QA/QC Checklist 149 

Stratification Sheet 151 

Interference Checks 153 

Test Protocol 155 

Certification Documentation 178 

Laboratory Analysis 188 

Gas Analyzer Calibration Data 203 

Analyzer Calibration Error 204 

System Bias and Drift 207 

Calibration Gas Certificates 214 

Equipment Calibrations 219 

Safety Documentation 236 

Nomenclature and Test Calculations 239 
Executive Summar V 

Boral Brick Company located in Terre Haute, Indiana retained Entec Services, Inc. to 

perform particulate matter emissions testing, HCI / HF, and SO2 on the DIFF Baghouse 

(Inlet and Outlet). Entec Services, Inc. also performed particulate matter emissions testing 

and VE's on the Clay Prep Dust Collector. Additionally, two buildings were monitored for 

Method 22. Mr. Tommy Lotz, Jr., Mr. Art Otero, Mr. David Bowman and Mr. Trent 

McMahan of Entec Services, Inc. conducted the testing on August 19 and 20, 2008. 

Representing Boral Brick Company was Ms. Mary Ann Keon who coordinated testing with 

the control room production activity. Mr. Jarrod Fisher, Mr. Pat Austin and Mr. Tom Kline 

represented the Indiana Department of Environmental Management. 

Entec Services, Inc. did not encounter any difficulties or problems during the sampling of 

these emissions sources, but did deviate from the Test Protocol (enclosed) slightly. It was 

proposed originally that Entec would perform two impinger method simultaneously on the 

DIFF outlet stack (Method 5/202 and 26A), but there wasn't enough room on the platform 

or enough ports to do this. Therefore, Entec performed three runs of 26A and 6C on the 

inlet and outlet of the DIFF. Following that test, Entec performed the particulate testing on 

the same day. The emissions test summaries on the following pages gives a detailed 

summary of each test run compared to the maximum emission limits set forth by the 

Indiana Department of Environmental Management and Vigo County Air Pollution Control 

permit No. T167-23205-00139. Tests results indicate the average emissions are 

below the limits set forth by IDEM and VCAPC for permit No. T167-23205-00139 for 

all testing except for the PMI0 on the Clay Prep Dust Collector which was above the 

limits. 

0 0 
Z 

0 
Detailed Test Results 
Entec Services, Inc. 

SOURCE OVERVIEW 

SOURCE OWNER: Boral Bricks 

PLANT LOCATION: 

SOURCE(S) NAME(S): 

Terre Haute, IN 

DIFF Inlet 

SOURCE(S) CONDITION.'. 

SOURCE(S) SHAPE: 

Intial C, nmplian¢.•. Testing 

Circular 

SOURCE PERMIT NUMBER: T167-23205-00139 

TEST PERFORMED: 

ADDITIONAL TEST REQUIREMENTS: 

REFERENCE METHOD TESTS: 

HCI / HF and Gaseous Testing 

Subpart JJJJJ 

Sample Location EPA Method 1 

Volumetric Flow EPA Method 2 

Molecular Weight EPA Method 3 

Moisture Content EPA Method 4 

Sulfur Dioxide EPA Method 6C 

HCI/HF EPA Method 26A 

PROJECT MANAGER Mr. Art Otero 

ENVIRONMENTAL ANALYST PROJECT LEADER 

ENVIRONMENTAL ANALYST ASSISTANT 

Mr. Tom Lotz, Sr. 

Mr. Trent McMahan 

OWNER'S REPRESENTATIVE: 

RULING AGENCY 

DATES TESTS CONDUCTED: 

Ms. Mary Ann Keon 

Indiana Department of Environmental Management 

and Vigo County Air Pollution Control 

08/20/08 

ENTEC PROJECT NUMBER: 28162 
ENTEC Services, Inc. 

16-D Commerce Ave. Hues'town, Alabama 35023 

INPUT TEST DATA 

Client: Boral Bricks Job No.: 28162 

Source: DIFF Inlet Data Input By: Tommy Lotz, Jr. 

Field Data Symbol Units Test Data 

Run Number 1 2 3 AVERAGE 

::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: 

Test Date 08/20/08 08/20/08 08/20/08 

Time Test Run Began Ended Military Time 0928-1032 1113-1219 1306-1409 

Sampling Time minutes 6O 6O 6O 

Stack Area A, Ft • 27.883 27.883 27.883 

Barometric Pressure Pb,, in. Hg 29.61 29.61 29.61 29.61 

60 

!Stack Static Pressure 

Pitot Tube Correction factor 

in. H•0 -0.57 -0.58 -0.57 -0.57 

0.84 0.84 0.84 0.84 

P• 

Cp 

Meter Correction Factor Y 0.978 0.978 0.978 0.978 

Meter Delta H @ z•H@ in. H20 1.856 1.856 1.856 1.856 

Nozzle Diameter D. inches 0.500 0.500 0.500 0.500 

Meter Volume v• dcf 38.950 44.763 43.484 42.399 

Meter Temperature t• °F 71.6 73.5 77.5 74.2 

Avg. Orifice Delta H •,H in. H20 1.30 1.80 1.69 1.60 

81.7 

7.6 

15.0 

Impingers Weight Gain (Moisture) 

Silica Gel Impinger Weight Gain (Moisture) 

grams 88.3 

13.5 

15,0 

grams 

94.1 

10.6 

15.0 

Wlmp 

W•g 

Oxygen Concentration, dry basis O2 

88.0 

10.6 

15.0 

Carbon Dioxide Concentration, dry basis co2 % 6.0 6.0 6.0 6.0 

Sulfur Dioxide Concentration, dry basis so2 ppm 137.6 132.8 130.2 133.53 

(in. H20) 0.192 

F 468.2 

Avg. Sq. Rt. of Delta P 0.219 

475.3 

(sqrt AP)ave 

Stack Temperature 

0.226 

471.9 

0.212 

471.8 

Total Hydrogen Chloride collected, mg HCL mg 18.2 19.8 19.1 19.0 

Total Hydrogen Fluoride collected, mg HF mg 78.9 101.0 94.5 91.5 
ENTEC Services, Inc. 

16-D CommerceAve. Huevtown, Alabama 35023 

CALCULATED TEST DATA 

Client: Boral Bricks Job No.: 28162 

Source: DIFF Inlet Data Input By: Tommy Lotz, Jr. 

Description Formulas Symbol Units Calculated Data 

Run Number 2 3 AVERAGE 

Test Date 08/20/08 08/20/08 08/20/08 iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii!iil 

1. Stack Pressure P•r Pg/13,6 Ps in. Hg 29.57 29.57 29.57 29.57 

2. Meter Pressure P•+L•H/13.6 Pm In. Hg 29.71 29.74 29.73 29.73 

3. Standard Meter Volume '17.64" Y* (V•,/T,•)* (P•r AH 3.6 V•(,• ds•f 37.551 43.053 41.499 40.701 

4a. Standard Volume of Water Vapor Condensed =0.04706*•Nim vwo¢,,,• scf 3.845 4.155 4.428 4.143 

4b. Standard Volume of Water Collected in Silica Gel =0.047t5"w,• vw,•,• sol 0.358 0.637 0.500 0.498 

5. Moisture Fraction =(v•t=d•+ V•,•d})/(v•[=t,l v,,•l,t•l v•l=•l) B,, fraction 0.1007 0.1002 0.1061 0.1023 

9. Molecular Weight Of Stack Gas, dry basis 0.32*(0=)+ 0.44"(c0=)+0,28-(100.(0•)-(co•)) M• g/g-mole 29.560 29.560 29.560 29.560 

10. Molecular Weight Of Stack Gas, wet basis Md*(1-B•)+lS.0*(B• Ms g/g-mole 28.396 28.402 28.333 28.377 

11. Average Stack Gas Velocity 85.49*Cp*(sqrt z•P)av.•*SQRT((T,) (P=*Mw)) fUs 14.49 17.11 16.59 16.064 

12. Stack Gas Flow @ Stack Conditions 60"v,*A, Q, acfm 24,246 28,621 27,760 26,876 

13. Stack Gas Flow @ Standard Conditions Q,*(T,te/]=)*(P,/P,•, Q= s•fm 13,625 16,018 15,480 15,041 

14. Stack Gas Flow @ Dry Standard Conditions Q=*(1-•}•)*(T=a/T,)*(PJP,•=j Q== dsofm 12,253 14,414 13,837 13,501 

14b. Hydrogen Chloride concentration @ Std.Cond.,Grains/Cu.Ft. =(0.01543*HCLme)/Q,•¢ HCLcs gr/dscf 0.007 0.007 0.007 0.007 

14b. Hydrogen Fluoride concentration @ Std.Cond.,Grains/Cu.Ft. =(0.01543*HF•g)/Q,•= HFes gr/dsef 0.032 0.036 0.035 0.035 

15b. Hydrogen Chloride emissions, Ibs per hour =(6017000)*HCLQ,•*Q• HCl-lb$/hr Ibs/hr 0.79 0.88 0.84 0.83 

15b. Hydrogen Fluoride emissions, Ibs per hour =(60/7000)*HFQ=ta*Q=• HF-Ibs/hr Ibs/hr 3.41 4.47 4.17 4.01 

16. Sulfur Dioxide (SO2) Gas Concentration =C•,•*MWl385.1 xl0 C=o= Ibs/dscf 2.29E-05 2.21E-05 2.17E-05 2.22E-05 

21. Sulfur Dioxide (SO2) Gas Concentration =Cso•* Q,{•* 60 SO=-Ib/hr Ib/hr 16.83 19.11 17.98 17.97 

22. Volume collected through nozzle =T,/Po*[0.002669*Vt•+ V•*Y*P,•I'•] V, a•f 74.304 85.489 83.259 81.017 

24. Isokinetic Samplin•l Rate, Percent t00*Vn/(60*v=*A,*g % 104.45 101.80 102.22 102.82 

Post Meter Orifice Cal. (EMC ALT-009 Yqa) y= ii!i!i!i!i!i!ii!i!i!i!i!ii!!!!ii!!i!iii!l 0.9666.. 0.9900 0.9892 0.9819 

% Difference, (Calibration must be within 5% of odglnal Y-factor) -0,40% 

10 
Entec Services, Inc. 

SOURCE OVERVIEW 

SOURCE OWNER: Boral Bricks 

PLANT LOCATION: Terre Haute, IN 

SOURCE(S) NAME(S): DIFF Inlet 

SOURCE(S) CONDITION: 

SOURCE(S) SHAPE: 

Intial Compliance Testing 

Circular 

PROBE WASH CHEMICAL: Acetone 

SOURCE PERMIT NUMBER: T167-23205-00139 

TEST PERFORMED: 

ADDITIONAL TEST REQUIREMENTS: 

REFERENCE METHOD TESTS: 

Particulate Testing 

Subpart JJJJJ 

Sample Location EPA Method 

Volumetric Flow EPA Method 2 

Molecular Weight EPA Method 3 

Moisture Content EPA Method 4 

Particulate EPA Method 5 

PROJECT MANAGER Mr. Art Otero 

ENVIRONMENTAL ANALYST PROJECT LEADER 

ENVIRONMENTAL ANALYST ASSISTANT 

Mr. Tommy Lotz, Jr. 

Mr. Trent McMahan 

ENVIRONMENTAL SPECIALIST VE READERS 

OWNER'S REPRESENTATIVE: 

Eddie Rudloff, Steve Speer, & Kevin Rosenberg 

Ms. Mary Ann Keon 

RULING AGENCY 

DATES TESTS CONDUCTED: 

Indiana Department of Environmental Management 

and Vigo County Air Pollution Control 

08/2O/08 

ENTEC PROJECT NUMBER: 28162 

11 
ENTEC Services, Inc. 

16-D Commerce Ave. Hue)•town, Alabama 35023 

INPUT TEST DATA 

Client: Boral Bricks Job No.: 28162 

Source: DIFF Inlet Data Input By: Tommy Lotz, Jr. 

Field Data Symbol 

Run Number 

Test Date 

Time Test Run Began Ended 

Sampling Time 

Stack Area 

Barometric Pressure 

Stack Static Pressure 

Pitot Tube Correction factor 

As 

Pbar 

P• 

Cp 

Y 

Units Test Data 

1 2 3 

Military Time 

minutes 

Ft 

in. Hg 

08/20/08 

1456-1558 

6O 

27.883 

29.61 

08/20/08 

1639-1743 

60 

27.883 

29.61 

08/20/08 

1817-1919 

60 

27.883 

29.61 

AVERAGE 

in. H20 -0.57 -0.58 -0.58 

0.84 0.84 0.84 0.84 

Meter Correction Factor 0.978 

Meter Delta H @ AH@ in. H20 1,856 

60 

29.61 

-0.58 

0.978 0.978 0.978 

1.856 1.856 1.856 

Nozzle Diameter D, inches 0.500 0.500 0.500 0.500 

Meter Volume v,, dcf 43,783 42,595 41.250 42.543 

Meter Temperature t• °F 78.9 79.4 75.6 78.0 

Avg. Orifice Delta H AH in. H20 1.80 1.74 1.50 1.68 

Impingers Weight Gain (Moisture) 

Silica Gel Impinger Weight Gain (Moisture) 

Wimp 

O2 

grams 87.0 82.9 85.8 85.2 

grams 13.0 7.6 9.4 10.0 

Oxygen Concentration, dry basis % 15.0 15.0 15.0 15.0 

Carbon Dioxide Concentration, dry basis co2 % 6.0 6.0 6.0 6.0 

Avg. Sq. Rt. of Delta P (sqrt AP)av• (in. H20) 0.229 0.225 0.209 0.221 

Stack Temperature t, °F 480.6 476.9 481.3 479.6 

Total particulate collected mn mg 29.5 33.1 52.2 38.3 

12 
ENTEC Services, Inc. 

16-D Commerce Ave. Hu•own, Alabama 35023 

CALCULATED TEST DATA 

Client: Boral Bricks Job No.: 28162 

Source: DIFF Inlet Data Input By: Tommy Lotz, Jr. 

Description Formulas Symbol Units 

Run Number 

Test Date 

Time Began-Ended Military Time 

1. Stack Pressure Pbar pg t3.6 Ps in. Fig 

2. Meter Pressure P•=r &H 113-6 Pm in. Hg 

3. Standard Meter Volume 17.64" Y* (Vm/Tm)* (Pb=r &H 13.6 Vm(,td} dscf 

4a. Standard Volume of Water Vapor Condensed =o.04706*w=m V•(=td} scf 

4b. Standard Volume of Water Collected in Silica Gel =0.04715*vv,g V•.•(=•d) scf 

5. Moisture Fraction =(v,o(,td) Vwsg(std})l(Vwc(std) V•g(std Vm{std)) B• fraction 

9. Molecular Weight Of Stack Gas, dry basis 0.32*(02)+ 0.44"(c02)+0.28"(I00.(02)-(c02) ad g/g-mole 

10. Molecular Weight Of Stack Gas, wet basis Md*(I-B,,)+lS.0*(B,,) M, gig-mole 

11. Average Stack Gas Velocity 85.49*Cp*(sqrt/•P)=va*SQRT((Ts) (Ps*M,)) v, ft/s 

12. Stack Gas Flow @ Stack Conditions 60*v,*A, Q, ecfm 

13. Stack Gas Flow @ Standard Conditions Qa*(Tst•/-rl)*(PslP,t=• Qs scfm 

14. Stack Gas Flow @ Dry Standard Conditions Qa*(I-Bw,)*(T, ta/T,)*(P,/P,ta', Q• dscfm 

15. Particulate concentration @ Standard Conditions =0.01543*m,Nm(std: c, gr/dscf 

21. Particulate emissions (60/7000)*cs*Q,= PMR Ib/hr 

22. Volume collected through nozzle =T•Ps*[0.002669*V=•+ Vm*Y*Pm/Tm] V, acf 

23. Particulate concentration, @ actual conditions =0,01543*m,N, c, grlacf 

24. Isokinetic Sampling Rate, Percent % 

Calculated Data 

2 3 AVERAGE 

29.57 29.57 20.57 20.67 

29.74 29.74 29.72 29.73 

41.686 40.512 39.490 40.563 

4.094 3.901 4.038 4.011 

0.613 0.358 0.443 0.472 

0.1015 0.0951 0.1019 0.0995 

29.560 29.560 29.560 29.560 

28,387 28.460 28.382 28.410 

17.41 17.07 15.89 16.794 

29,132 28,565 26,591 28,096 

16,154 15,902 14,735 15,597 

14,515 14,389 13,233 14,046 

0.0109 0.0126 0.0204 0.0146 

1.36 1.55 2.31 1.74 

83.664 80.427 79.354 81.148 

0.0054 0.0064 0.0102 0.0073 

100*Vn (60*v=*An*6 97.88 95.96 101.71 98.52 

% Difference, (Calibration must be within 5% of original Y-factor) -3,05% 

13 
Entec Services, Inc. 

SOURCE OVERVIEW 

SOURCE OWNER: Boral Bricks 

PLANT LOCATION: Terre Haute, IN 

SOURCE(S) NAME(S): DIFF Outlet 

SOURCE(S) CONDITION: 

SOURCE(S) SHAPE: 

Intial Compliance Testing 

Circular 

SOURCE PERMIT NUMBER: T167-23205-00139 

TEST PERFORMED: 

ADDITIONAL TEST REQUIREMENTS: 

REFERENCE METHOD TESTS: 

HCI / HF and Gaseous Testing 

Subpart JJJJJ 

Sample Location EPA Method 

Volumetric Flow EPA Method 2 

Molecular Weight EPA Method 3 

Moisture Content EPA Method 4 

Sulfur Dioxide EPA Method 6C 

HCI / HF EPA Method 26A 

PROJECT MANAGER Mr. Art Otero 

ENVIRONMENTAL ANALYST ASSISTANT Mr. David Bowman 

OWNER'S REPRESENTATIVE: 

RULING AGENCY 

DATES TESTS CONDUCTED: 

Ms. Mary Ann Keon 

Indiana Department of Environmental Management 

and Vigo County Air Pollution Control 

08/20/08 

ENTEC PROJECT NUMBER: 28162 

14 
ENTEC Services, Inc. 

16-D Commerce Ave. Hues(town, Alabama 35023 

INPUT TEST DATA 

Client: Boral Bricks Job No.: 28162 

Source: DIFF Outlet Data Input By: Art Otero 

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 @ 

Nozzle 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 

'Sulfur Dioxide Concentration, dry basis 

Avg. Sq. Rt. of Delta P 

Stack Temperature 

Total Hydrogen Chloride collected, mg 

Total Hydrogen Fluoride collected, mg 

Symbol 

As 

ebar 

P9 

Cp 

Y 

&H@ 

Dn 

Vm 

tm 

AH 

Wimp 

Ws• 

CO• 

SO2 

(sqrt/•P)av• 

Units 

Military Time 

minutes 

Ft 

in. Hg 

in. H20 

in. Hz0 

inches 

dcf 

F 

in. HzO 

grams 

grams 

ppm 

(in. H20) 

Test Data 

1 2 

08/20/08 08/20/08 

0928-1030 

6O 

26.725 

29.61 

-0.20 

0.84 

1.018 

1.753 

0.310 

33.117 

74.1 

0.99 

45.3 

6.8 

17.0 

3.0 

61.1 

1114-1216 

6O 

26.725 

29.61 

-0.22 

0.84 

1.018 

1.753 

0.310 

31.696 

77.8 

0.87 

44.8 

7.4 

17.0 

3.0 

62.3 

0.402 0.378 

3 

08/20/08 

1307-1409 

6O 

26.725 

29.61 

-0.21 

0.84 

1.018 

1.753 

0.310 

33.266 

80.7 

0.94 

47.6 

6.8 

17.0 

3.0 

AVERAGE 

:::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: 

"i!"i'i'i'i:i'ii"i:•'i'i'i';'i'i'i'i'ii'i'i 

6O 

29.61 

-0.21 

0.84 

1.018 

1.753 

0.310 

32.693 

77.5 

0.93 

45.9 

7.0 

17.0 

3.0 

60.9 61.43 

0.393 0.391 

t• °F 300.7 304.6 307.6 304.3 

HCL mg 1.6 1.5 1.8 1.6 

HF mg 0.02 0.02 0.02 0.02 

Less Than 

15 
ENTEC Services, Inc. 

16-D Commerce Ave. Hueytown, Alabama 35023 

CALCULATED TEST DATA 

Client: Boral Bricks Job No.: 28162 

Source: DIFF Outlet Data Input By: Art Otero 

Description Formulas Symbol Units Calculated Data 

Run Number 2 3 AVERAGE 

1. Stack Pressure P•r Pg 13.6 P. in. Hg 29.60 29.59 29.59 29.59 

2. Meter Pressure Pb=, •H 113.( P, in. Hg 29.68 29.87 29.88 29.68 

3. Standard Meter Volume 17.64" Y* (Vm/Tm)* (P•, ,•H 13.6', V,W= 

4a. Standard Volume of Water Vapor Condensed =O.04706*W[me Vw¢lst 

4b. Standard Volume of Water Collected in Silica Gel =0.04715"W=• V,=•(=u) 

5. Moisture Fraction 

3. Moisture Fraction @ Saturation (Theoretical) 

7. Standard Water Volume @ Saturation !Theoretical! 

•. Volume of Water @ Saturation (Theoretical) 

9. Molecular Weight Of Stack Gas, dry basis 

10. Molecular Weight Of Stack Gas, wet basis 

11. Average Stack Gas Velocity 

12. Stack Gas Flow @ Stack Conditions 

85.49*Ce*($qrt ,•P)=v•*SQRT((T=) (P=*Mw)) 

60•,=*A= 

13. Stack Gas Flow @ Standard Conditions Q=*(T,•¢/T=)*(P=/P=t•) 

14. Stack Gas Flow @ Dry Standard Conditions 

14b. Hydrogen Chlodde concentration @ Std.Cond.,Grains/Cu.Ft. =(0.01543*HCLm•}IQ=d 

dscf 33.053 31.408 32.793 32.418 

scf 2.132 2.108 2.240 2.160 

scf 0.321 0.349 0.321 0.330 

14b. Hydrogen Fluoride concentration @ Std.Cond.,Grains/Cu.Ft. 

15b. Hydrogen Chloride emissions, Ibs per hour 

fra©tion 0.0691 0.0726 0.0724 0.0714 

fraction 4.4722 4.7382 4.9482 4.7195 

scf -42.573 -39.811 -41.099 -41.161 

ml -904.5 -845.8 -873.1 -874.5 

g/g-mole 29.160 29.160 29.160 29.160 

gig-mole 28.389 28.350 28.352 28.364 

15b. Hydrogen Fluoride emissions, Ibs per hour 

fus 27.47 25.88 26.97 26.772 

16. Sulfur Dioxide (SO2) Gas Concentration 

acfm 44,046 41,499 43,245 42,930 

21. Sulfur Dioxide (SO 2) Gas Concentration 

22. Votume collected through nozzle 

Q, scfm 30,230 28,334 29,411 29,325 

• d$¢fm 28,142 26,278 27,281 27,234 

HCLcs 

=(O.01543*HFmR)/Q=•d HFcs 

=(6017000)*HCLQ=a*Q•a HCl -Ibs/hr 

=(6017000)*HFQ=td*Q•e HF -Ibslhr 

=C.q• MW 1385.1 10 C=o= 

=Ceo= Q=¢d 60 SO=-Ib/hr 

=T=/P.*[0.002669*V=,+ V•*Y*P•/Tm] V, 

gr/dscf 7.24E-04 7.22E-04 8.38E-04 7.61E-04 

gr/dscf 9.34E-06 9,83E-06 9,41E-06 9.52Eo06 

Ib==lhr 0.17 0.16 0.20 0.18 

Ibslhr 0.002 0.002 0•002 0;002 

Ib$1dsef 1.02E-05 1.04E-05 1.01E-05 1.02E-05 

Iblhr 17.16 16.34 16.58 16.69 

acf 51.733 49.602 51.983 51.106 

24. Isokinetic Sampling] Rate, Percent 100*Vnl (60*v.*A.*8) % 99.81 101.57 102.15 101.18 

Post MeterOrificeCal.(EMCALT-009Yqa) y•, Iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiil 1.0266 ]1.0116 ]1.0028 1.0137 

16 
Entec Services, Inc. 

SOURCE OVERVIEW 

SOURCE OWNER; Boral Bricks 

PLANT LOCATION; Terre Haute, IN 

SOURCE(S) NAME(S): DIFF Outlet 

SOURCE(S) CONDITION: 

SOURCE(S) SHAPE: 

Intial Compliance Testing 

Circular 

PROBE WASH CHEMICAL: Acetone 

SOURCE PERMIT NUMBER: T167-23205-00139 

TEST PERFORMED: 

ADDITIONAL TEST REQUIREMENTS: 

REFERENCE METHOD TESTS: 

Particulate Testing 

Subpart JJJJJ 

Sample Location 

Volumetric Flow 

Molecular Weight 

Moisture Content 

Particulate 

Condensible Particulate 

EPA Method 

EPA Method 

EPA Method 

EPA Method 

EPA Method 

EPA Method 

2 

3 

4 

5 

2O2 

PROJECT MANAGER Mr. Art Otero 

ENVIRONMENTAL ANALYST ASSISTANT Mr. David Bowman 

OWNER'S REPRESENTATIVE: 

RULING AGENCY 

DATES TESTS CONDUCTED: 

Ms. Mary Ann Keon 

Indiana Department of Environmental Management 

and Vigo County Air Pollution Control 

08/20/08 

ENTEC PROJECT NUMBER: 28162 

17 
ENTEC Services, Inc. 

16-D Commerce Ave. Hues'town, Alabama 35023 

INPUT TEST DATA 

Client: Boral Bricks Job No.: 28162 

Source: DIFF Outlet Data Input By: Art Otero 

Field Data Symbol Units Test Data 

Run Number 

Test Date 

Time Test Run Began Ended Military Time 

1 2 3 

08/20/08 08/20/0R 08/20/08 

1457-1558 1639-1740 1817-1919 

SampliBg Time e minutes 60 60 60 

Stack A•a A, F£ 26.725 26.725 26.725 

in. Hg 

P• 

Cp 

Y 

29.59 

-0.19 

0.84 

1.018 

Barometric Pressure 

Stack Static Pressure 

Pitot Tube Correction factor 

Meter Correction Factor 

29.59 

-0.21 

0.84 

1.018 

in. H20 

29.59 

-0.17 

0.84 

1.018 

AVERAGE 

60 

29.59 

-0.19 

0.84 

1.018 

Meter Delta H @ ,•H@ in. H20 1.753 1.753 1.753 1.753 

Nozzle Diameter D, inches 0.310 0.310 0.310 0.310 

Meter Volume 

Meter Temperature 

Avg. Odfice Delta H 

Impingers Weight Gain (Moisture) 

Silica Gel I.mpinger Weight Gain (Moisture) 

Vm dcf 32.008 32.821 31.971 32.267 

t• °F 83.3 82.4 79.3 81.6 

•H in. H•O 

Wirnp 

Ws• 

O• 

0.90 0.90 0.89 0.90 

grams 40.0 35.9 37.2 37.7 

grams 8.3 11.4 13.5 11.1 

Oxygen Concentration, dry basis % 17.0 17.0 17.0 17.0 

Carbon Dioxide Concentration, dry basis co2 % 3.0 3.0 3.0 3.0 

(in. H20) 1/2 

F 

mg 

(sqrt ,•P),• 0.377 

310.0 

54.8 

12.8 

ts 

mo + mi mb 

Avg. Sq. Rt. of Delta P 

Stack Temperature 

Total condensible particulate collected 

Total particulate collected 

0.376 

309.1 

54.4 

12.6 

0.379 

308.6 

65.5 

0.377 

309.2 

58.2 

7.6 11.0 mn mg 

18 
ENTEC Services, Inc. 

16-D Commerce Ave. Hu•town, Alabama 35023 

CALCULATED TEST DATA 

Client: Boral Bricks Job No.: 28162 

Source: DIFF Outlet Data Input By: Art Otsro 

Description Formulas Symbol Units 

Run Number 

Test Date 

Time Began-Ended Military Tim• 

1. Stack Pressure P•,=, P• t3.E Ps in. Hg 

2. Meter Prassure Pb=r •H 13.£ P• in. Hg 

3. Standard Meter Volume 17.64" Y* (Vm/Tm)* (Pb=r AH 13.61 Vm(=a) dscf 

4a. Standard Volume of Water Vapor Condensed =0.04706"w• v•(=al scf 

4b. Standard Volume of Water Collected in Silica Gel =0.04715"w,• v•(•td) scf 

5. Moisture Fraction =(vw=(,t,) V•g(.td))/(Vw¢(itd) V•g(std) Vm(std)] B• fraction 

9. Molecular Weight Of Stack Gas, dry basis 0.32"(O•)+ 0.44"(C02)+0.28"(100-(0z)-(co2)] Md g/g-mole 

10. Molecular Weight Of Stack Gas, wet basi• M•*(I-Bw,)+18.0*(B•} M, g/g-mole 

1. Average Stack Gas Velocity 85.49*Cp*(sqrt &P)=vg*SQRT((T,) (P,*Mw) vs ft/s 

12. Stack Gas Flow @ Stack Conditions 60*v,*A, Q, acfm 

13. Stack Gas Flow @ Standard Conditions Q=*(T,•dCI',)*(P,/P,td} Q= scfm 

14. Stack Gas Flow @ Dry Standard Conditions Q=*(I-B•)*(T, td/T,)*(P•/Pstd) Q,¢• dscfm 

15. Particulate concentration @ Standard Conditions =0.01543*mnNml,td] C= grldscf 

15. PM10 concentration @ Standard Conditions =0.01543*m,N•(,t•l gr/dscf 

21. Particulate emissions (60/7000)*c,*Q,d PMR Ib/hr 

21. PM10 emissions (60/7000)*cs*Q,d PMR Ib/hr 

22. Volume collected through nozzle =T=IP=*[O.OO2669*Vz•+ V•*Y*Pm/Tm] Vn acf 

23. Particulate concentration, @ actual conditions =0.01543*m,Nn c= grlacf 

24. Isokinetic Sampling Rate, Percent % 

Calculated Data 

2 3 AVERAGE 

29.58 29.57 29.58 29.58 

29.66 29.66 29.66 29.66 

31.378 32.228 31.570 31.725 

1.882 1.689 1.751 1.774 

0.391 0.538 0.637 0.522 

0.0676 0.0646 0.0703 0.0675 

29.160 29.160 29.160 29.160 

28.406 28.439 28.375 28.407 

26.05 25.91 25.82 25.928 

41,778 41,548 41,400 41,575 

28,358 28,150 28,087 28,199 

26,442 26,330 26,113 26,295 

0.0037 0.0061 0.0062 0.0053 

0.0359 0.0324 0.0328 0.0337 

0.85 1.39 1.38 1.20 

8.14 7.31 7.33 7.59 

49.576 50.853 50.052 50.161 

0.0024 0.0039 0.0039 0.0034 

100*Vn (60*v,*A,*e) 00.84 104.01 102.74 102.53 

19 
Entec Services, Inc. 

SOURCE OVERVIEW 

SOURCE OWNER: 

PLANT LOCATION= 

SOURCE(S) NAME(S): 

SOURCE(S) CONDITION," 

SOURCE(S) SHAPE; 

PROBE WASH CHEMICAL= 

SOURCE PERMIT NUMBER= 

TEST PERFORMED: 

ADDITIONAL TEST REQUIREMENTS: 

REFERENCE METHOD TESTS: 

PROJECT MANAGER 

ENVIRONMENTAL ANALYST PROJECT LEADER 

ENVIRONMENTAL ANALYST ASSISTANT 

ENVIRONMENTAL SPECIALIST VE READERS 

OWNER'S REPRESENTATIVE: 

RULING AGENCY 

RULING AGENCY REPRESENTATIVE; 

DATES TESTS CONDUCTED; 

ENTEC PROJECT NUMBER." 

Boral Bricks 

Terre Haute, Indiana 

Clay Preparation Dust Collector 

Initial Compliance Testing 

Ciroular 

Acetone 

T167-23205-00139 

Particulate Testing 

Subpart OOO, requires at least 60 cubic feet 

Sample Location 

Volumetric Flow 

Molecular Weight 

Moisture Content 

Particulate 

Visible Emissions 

Fugitive Emissions 

Condensible Particulates 

Mr. Art Otero 

Mr. Tommy Lotz, Jr. 

Mr. David Bowman 

Mr. Trent McMahan 

Ms. Mary Ann Keon 

Indiana Department of Environmental Management 

and Vigo County Air Pollution Control 

Mr. Jarrod Fisher, Mr. Pat Austin, and Mr. Tom Kline 

08/19/08 

28162 

EPA Method 

EPA Method 

EPA Method 

EPA Method 

EPA Method 

EPA Method 

EPA Method 

EPA Method 

2 

3 

4 

5 

9 

22 

202 

2O 
ENTEC Services, Inc. 

16-D Commerce Ave. Hue•town, Alabama 35023 

INPUT TEST DATA 

Client: Boral Bricks Job No.: 28162 

Source: Clay Preparation Dust Collector Data Input By: Art Otero 

Field Data 

Run Number 

rest Date 

Time Test Run Began Ended 

'Sampling Time 

Stack Area 

Barometric Pressure 

Stack Static Pressure 

Pitot Tube Correction factor 

Meter Correction Factor 

Symbol Units Test Data 

1 2 3 AVERAGE 

Military Time 0945-1124 1204-1343 1408-1546 

As 

ebar 

P• 

Cp 

Y 

minutes 

Ft 

in. Hg 

96 

10.321 

29.60 

96 

10.321 

29.60 

96 

10,321 

29.60 

96 

29.60 

in. H20 -13.20 -13.00 -13.00 -13.07 

0.84 0.84 0.84 0.84 

1.018 1.018 1.018 1.018 

Meter Delta H @ b.H@ in. H20 1.753 1,753 1.753 1.753 

Nozzle Diameter Dn inches 0.176 0.176 0.176 0.176 

Meter Volume vm dcf 65.684 67.214 68.231 67.043 

Meter Temperature tm °F 81.3 91.1 97.3 89.9 

in. H20 1.49 1.50 1.55 1.51 

grams 21.2 19.0 18.6 19.6 

grams 

(in. H20) 

F 

Avg. Orifice Delta H 

Impingers Weight Gain (Moisture) 

Silica Gel Impinger Weight Gain (Moisture) 

•H 

14.7 17.8 22.4 18.3 

20.5 20.5 20.5 20.5 

0.0 

1.216 

74.5 

7.2 

9.0 

Wimp 

02 

C02 

(sqrt '•P)av• 

mo + ml- mb 

0.0 

1.219 

79.9 

11.1 

mn 13.8 

Oxygen Concentration, dry basis 

Carbon Dioxide Concentration, dry basis 

Avg. Sq. Rt. of Delta P 

0.0 

1.239 

83.0 

4.4 

8.5 

Stack Temperature 

Total condensible particulate collected 

Total particulate collected 

mg 

mg 

0.0 

1.225 

79.1 

7.6 

10.4 

21 
ENTEC Services, Inc. 

16-D Commerce Ave. Hue•town, Alabama 35023 

CALCULATED TEST DATA 

Client: Boral Bricks Job No.: 28162 

Source: Clay Preparation Dust Collector Data Input By: Art Otero 

Description Formulas Symbol Units Calculated Data 

Run Number 

Test Date 

Time Began-Ended Military Time 

!1. Stack Prassure P•T P• '13.6 P• in. Hg 

2. Meter Pressure Pt•r •'H 13.6 Pm in. Hg 

3. Standard Meter Volume t7.64" Y* (vr•rm)* (Pt•r •H 113.6} V,.4,•d dscf 

4a. Standard Volume of Water Vapor Condensed =o.04706*w•m• v•l=•, scf 

4b. Standard Volume of Water Collected in Silica Gel =0.04715"w=• v•,,,•(,,al scf 

5. Moisture Fraction =(v•{,td) V•g(,td))/(Vwc(,td) V•g(•td) Vm(=¢d}l B• fraction 

6. Moisture Fraction @ Saturation (Theoretical) =t0[•'•z•l•'*•°'•'ZllP TB• fraction 

7. Standard Water Volume @ Saturation (Theoretical) =v,•=•)* (TB•)/(1-TB•} l•/w(,,•} scf 

8. Volume of Water @ Saturation (Theoretical) =TVw{std)10.04707 TV,¢ ml 

9. Molecular Weight Of Stack Gas, dry basis 0.32"(0=)÷ 0.44"(c0•)+0.28"(100-(0z)-(c0•)) Ma g/g-mole 

10. Molecular Weight Of Stack Gas, wet basis M•*(1-B•)+IS.0*(B•) M, g/g-mole 

11. Average Stack Gas Velocity 85.49*C,*(sqrt •P),vg*SQRT((T=) (P,*M,)) v, ffJs 

12. Stack Gas Flow @ Stack Conditions 60*v,*A, Q, acfm 

13. Stack Gas Flow @ Standard Conditions Q=*(T,¢a/T,)*(PJP,¢•) (3= scfm 

14. Stack Gas Flow @ Dry Standard Conditions Q,*(1-Bw•)*(Tstd/Ts)*(P=/P=td) Q•d dscfm 

15. Particulate concentration @ Standard Conditions =0.01543*m,N•($t•) c= gr/dscf 

15. PM10 concentration @ Standard Conditions =0.01543*mnNm(std) gr/dscf 

21. Particulate emissions (60/7000)*c=*Q=a PMR Ib/hr 

21. Particulate emissions (60/7000)*c=*Q=a PM10R Ib/hr 

22. Volume collected through nozzle =T=/p=*[0.002669*V•=+ Vm*Y*Pm/T•] V, acf 

23. Particulate concentration, @ actual conditions =0.01543*m,N, c, gr/acf 

24. Isokinetic Sampling Rate, Percent % 

2 3 AVERAGE 

0945-1124 1204-1343 1408-1546 :::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: 

28.63 28.6,1 28.64 28.64 

29.71 29.71 29.71 29.71 

64.735 65.067 65.323 65.042 

0.998 0.894 0.875 0.922 

0.693 0.839 1.056 0.863 

0.0255 0.0259 0.0287 0.0267 

0.0301 0.0360 0.0397 0.0353 

2.009 2.429 2.704 2.381 

42.7 51.6 57.4 50.6 

28.820 28.820 28.820 28.820 

28.545 28.539 28.509 28.531 

70.64 71.15 72.53 71.440 

43,742 44,061 44,913 44,239 

41,327 41,234 41,797 41,452 

40,275 40,164 40,596 40,345 

0.0021 0.0033 0.0020 0.0025 

0.0039 0.0059 0,0030 0.0043 

0.74 1.13 0.70 0.85 

1.33 2.03 1.06 1.47 

70.308 71.379 72.268 71.318 

0.0020 0.0030 0.0018 0.0023 

•00*Vn (g0*v,*A,*e) 102.28 103.09 102.39 102.58 

Difference, (Calibration must be within 5% of original Y-factor) ii;iiiiiii;iiiiiiiiiiii?:;ii::iiii;::iiiiiiiii::iiii!ii!!iil iii!ii::iil;::!;iii;iii;i;i::::::::i::::ii::i::i::iiii::::iiiiiiiiiiiiii -0.69% 

22 
Sampling Procedures 
Proced u res 

Tunnel Kiln/DIFF Baghouse Inlet PM, HCI/HF & SO2 (EU02) 

Testing was conducted for particulate, hydrogen chloride, hydrogen fluoride, and sulfur 

dioxide per the requirements of Part 63 Subpart JJJJJ (Brick MACT) using EPA methods 

1-5, 26A, and 6C of the CFR Title 40, Part 60, Appendix A. The sulfur dioxide emissions 

were used to determine removal efficiency per PSD Minor source permit requirements. 

The hydrogen chloride and hydrogen fluoride results were used to determine the DIFF 

removal efficiency for these compounds as per the requirements of Part 63, Subpart 

JJJJJ. The first train (26A) was used to collect the HCI and HF samples. A second train 

(5) was used to collect the PM samples. The gas train (6C) was used to collect the sulfur 

dioxide samples. 

Stack Gas Volumetric Flow 

The velocity of the gas stream was determined according to EPA Reference Method 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 tested for cyclonic flow according •o EPA Reference Method 2. 

Stack Gas Molecular Weight 

The carbon dioxide and oxygen concentrations were determined using EPA Reference 

Method 3. A grab sample of the flue gas was extracted from the gas stream during each 

particulate test run and analyzed using a Fyrite analyzer. The molecular weight of the gas 

was calculated using the moisture, oxygen and carbon dioxide content and the measured 

stack gas temperature. The Fyrite sampling system was verified to be leak free prior to the 

analysis. 

Moisture Content (Method 4) 

The moisture content used for calculating the gas stream flow rate is determined by 

measuring the amount of condensed moisture in the series of impingers in the sampling 

train as described in EPA Reference Method 4 at the completion of each test. The 

24 
moisture collection system consists of a series of impingers. Ice is placed around the 

impingers to maintain a temperature <68 o F. 

Sulfur Dioxide 

Samples are extracted from the gas stream by a heated stainless steel probe maintained 

at a set temperature of 250 degrees Fahrenheit, through a ten (10) foot heated sample 

line that is heated to a temperature between 225 and 250 degrees, through a chilled 

sample conditioner to remove the moisture in the gas stream and transported to the test 

trailer through unheated teflon sample lines to the analyzers. 

Concentration values are collected using a Baldwin Environmental RM Plus Parametrics 

data acquisition system. The data is recorded every fifteen-seconds and then averaged for 

each sixty-second interval. Each minute average is then averaged for the duration of each 

test run. 

During all testing, the unit was operating within normal operating parameters; at a range 

appropriate in accordance with applicable permits. 

A Western Research Model 721M SO2 analyzer (or equivalent) provided continuous 

analysis of SO2 in the gas stream. The basic analytical principle involves quantitative 

measurement of the absorption of UV radiation by SO2 molecules. The analyzer uses a 

single light source, which emits an appropriate wavelength, illuminating the sample cell 

through which the sample is continuously passed. Narrow-band optical filters are rotated 

through the beam, and the radiation passed through the optical filters and sample cell is 

detected by a single photo-detector. The signal pulses from the photo-detector are 

separated by a multiplexor into a measuring channel and a reference channel. A log ratio 

amplifier computes the logarithm of the input signal ration, producing a signal that is 

proportional to the SO2 concentration. The dual-range analyzer has a digital readout, as 

well as 0-10.0 V DC output terminals. The full scale of the instrument was set at 454.3 

ppm. 

Samplin.q System 

The new test requirements require a stratification test which was performed and it was 

determined that the gas stream was unstratified and has been included in the QA / QC 

25 
section of this report. The gas samples were collected from a a single point that most 

closely matches the mean of the stratification test data. Samples were extracted from the 

gas stream by a heated stainless steel probe maintained at a set temperature of 250 

degrees Fahrenheit, through a hundred (100) foot heated sample line that was heated and 

maintained at a temperature between 225 and 250 degrees. The gas is transported to the 

test trailer then passed through a chilled sample conditioner to remove the moisture in the 

gas stream and then to the analyzers. 

Data Acquisition 

Concentration values were collected using a Baldwin Environmental RM Plus Parametrics 

data acquisition system. The data was recorded every fifteen-seconds and then averaged 

for each sixty-second interval. Each minute average was then averaged for the duration of 

each test run. 

Particulate Determination 

The particulate sample train consists of a heated sample probe and glass liner equipped 

with a S-type Pitot tube and thermocouple. The probe is attached to a sample module 

consisting of a heated filter compartment which houses the in-line filter holder equipped 

with a pre-weighed glass fiber filter for the collection of the particulate. A thermocouple 

located to within one inch of the back of the filter is located in the gas stream. This 

thermocouple regulates and maintains the correct temperature at the filter. The sample 

module is connected to a series of impingers for the collection of the condensed moisture. 

The sample module is connected to a control module by means of an umbilical cord. The 

control module consist of a dry gas meter, calibrated orifice, leak free pump, two inclined 

manometers, temperature controllers for the heated filter compartment and probe and a 

thermocouple indicator to monitor the required temperatures during the testing. 

Particulate samples are collected as follows: The sample gas is drawn through the 

sampling probe isokinetically and passed through a 3-inch Whatman glass fiber filter 

where particulates are removed. The exit of the filter was maintained at a temperature of 

248 0 F +/- 25 degrees. These temperatures were recorded at each point on the data 

sheets. 

26 
The sample gas is then pulled through the impinger train. The sample gas then passes 

through a vacuum pump followed by a dry gas meter. The dry gas meter integrates the 

sample gas flow throughout the duration of the test. A calibrated orifice attached to the 

outlet of the dry gas meter provides real time flow rate data. 

A representative particulate sample is acquired by sampling for equal periods of time at 

the centroid of a number of equal area regions in the exhaust stack. The sampling rate is 

adjusted at each test point maintaining an isokinetic sampling condition. 

After the sampling is complete, the filter is removed and placed in a storage container for 

shipment back to the laboratory for analysis. The nozzle, probe liner and inlet side of the 

filter holder are quantively washed with a reagent grade acetone and stored in a marked 

and sealed container. The samples are transferred back to the laboratory were they are 

logged in and analyzed. The volume of acetone rinse is noted and transferred to a tarred 

beaker and evaporated off at 97-105 °F. This temperature is used to prevent condensation 

of atmospheric moisture due to the cooling effects induced by the evaporating acetone. 

The acetone-free sample is placed in an oven and dried at 105 °C for thirty minutes and 

then placed in a desiccator. After the sample has desiccated for twenty-four hours the 

sample is weighed to the nearest 0.1 mg. The filter sample is transferred to the original 

petri dish in which the original weight was obtained and placed in a drying oven for 2 hours 

at 105 °C. The filter and petri dish are then placed in a desiccator. After the filter and petri 

dish have desiccated for twenty-four hours the sample is weighed to the nearest 0.1 mg. 

Visual examination of the samples are made to determine if any unusual characteristics of 

the samples are observed. The weight of the acetone rinse is corrected for the weight of 

the acetone blank. 

HCI / HF (Method 26A) 

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 were 

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 was also recorded on the data sheets. 

27 
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 probe and filter was 

maintained at the proper setting to obtain a temperature of greater than 248 0 F. The 

gases then proceeded through borosilicate glass filter holder, with a Teflon frit filter 

support through a tarred Teflon or quartz fiber filter to remove particulate matter. 

The gases then scrubbed through a series of five impingers (optional impinger not 

included) to capture hydrogen halides and halogens and moisture. The optional first 

impinger for a knockout for moisture was not be used since the source is a dry baghouse 

system. The second and third impingers contain approximately 100 ml of a 0.1N H2SO4 

solution and the fourth and fifth impingers contain approximately 100 ml of a 0.1 N N•OH 

solution. The sixth impinger contains pre weighed silica gel to remove any remaining 

moisture. The gases pass through the impinger series in an ice bath to maintain a 

maximum exit temperature of 68 0 F. This temperature was also recorded on the data 

sheets. The clean and cool gases then entered the meter box where the gas flow and 

temperature were measured. 

Test Note The inlet duct configuration, which was located vertically on the top of the 

circular duct did 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 be securely located in the man lift platform below the port. To keep from breaking the 

connection of the sample train during the rotation in ports the impinger train was not 

disconnected for the entire test to help eliminate the possibility of leaks during the testing. 

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 to be included into the analysis. 

After the completion of the test, leak rate determinations were made. Then the sampling 

train and the probe nozzle assembly were transferred to the cleanup area making sure no 

particulate was lost. The cleanup data was recorded. 

The first and second impinger contents were transferred to its tarred container, weighed 

and the rinsing from the glassware was added to this container. The third and fourth 

impinger contents were transferred to its respective tarred container, weighed and the 
rinsing from the glassware was added to this container. The silica gel from the fifth 

impinger was transferred to its respective tarred container and weighed. A blank of the 

sulfuric acid solution and distilled water was taken. These containers were clearly marked 

and transported to the laboratory for analysis. 

DIFF Baqhouse Outlet PM, PMI_0, HCI, HF, and SO_• (CD01) 

Testing was conducted for particulate, PMlo, hydrogen chloride, hydrogen fluoride, and 

sulfur dioxide per the requirements of Part 63 Subpart JJJJJ (Brick MACT) using EPA 

methods 1-5 with 202, 26A, and 6C of the CFR Title 40, Part 60, Appendix A and Part 51, 

Appendix M. The hydrogen chloride and hydrogen fluoride results were used to determine 

the DIFF removal efficiency and the emission limits of these compounds as per the 

requirements of Part 63, Subpart JJJJJ. The particulate, PM10, and sulfur dioxide results 

were used to determine the permit emission limits. The first train (26A) was used to collect 

the HCI and HF samples. A second train (5/202) was used to collect the PM and PM•0 

samples. The gas train (6C) was used to collect the sulfur dioxide samples. 

Stack Gas Volumetric Flow 

Same as EU02 procedures 

Stack Gas Molecular Weight 

Same as EU02 procedures 

Moisture Content 

Same as EU02 procedures 

Particulate Determination 

Same as EU02 procedures 

Condensable Particulate Determination 

The condensable particulate is collected in the impinger portion of the Method 5 sampling 

train. If the pH is less than 4.5, the impinger contents are purged after each run with 

nitrogen to remove dissolved sulfur dioxide gases from the impinger contents. The pH for 

each run is recorded on the field data sheets. The impinger solutions are extracted with 

laboratory grade Methylene Chloride. The organic and inorganic fractions are extracted 

29 
using separatory funnels. The organic extract is evaporated at room temperature and 

desiccated for 24 hours or to dryness and the residues weighed. The inorganic fraction is 

evaporated using a hot plate to approximately 50 ml then evaporated to dryness in a 

105°C oven. 

Sulfur Dioxide 

A Ametek Model 900 SO2 analyzer (or equivalent) will provide continuous analysis of SO2 

in the gas stream. The basic analytical principle involves quantitative measurement of the 

absorption of UV radiation by SO2 molecules. The analyzer uses a single light source, 

which emits an appropriate wavelength, illuminating the sample cell through which the 

sample is continuously passed. Narrow-band optical filters are rotated through the beam, 

and the radiation passed through the optical filters and sample cell is detected by a single 

photo-detector. The signal pulses from the photo-detector are separated by a multiplexor 

into a measuring channel and a reference channel. A log ratio amplifier computes the 

logarithm of the input signal ration, producing a signal that is proportional to the SO2 

concentration. The dual-range analyzer has a digital readout, as well as 0-10.0 V DC 

output terminals. The full scale of the instrument was set at 89.6 ppm. 

HCI and HF 

Same as EU02 procedures except that impinger train was connected to the hotbox. 

Clay Preparation Dust Collector Stack PM, PM•0, and VE's (CD02) 

Testing was conducted for particulate, PM10, and visible emissions per the requirements of 

Part 60 Subpart OOO using EPA methods 1-5 with 202, 22, and 9 of the CFR Title 40, 

Part 60, Appendix A and Part 51, Appendix M. The particulate, PM10, and visible emission 

results will be used to determine the permit emission limits. One train (5/202) will be used 

to collect the PM and PM10 samples. 

Stack Gas Volumetric Flow 

Same as CD01 procedures 

Stack Gas Molecular Weight 

Same as CD01 procedures 

3o 
Moisture Content 

Same as EU02 procedures 

Particulate Determination (OOO) 

Same as CD01 procedures except that the sampling probe was placed at each sampling 

point to provide a total sampling time of at least 60-120 minutes and a volume of at least 

60.0 cubic feet per Subpart OOO. 

Condensable Particulate Determination 

Same as CD01 

Visible Emissions 

The qualified observer stood at a distance sufficient to provide a clear view of the 

emissions with the sun oriented in the 140 ° sector to his back. Consistent with maintaining 

the above requirement, the observer did, as much as possible, make his observations 

from a position such that his line of vision is approximately perpendicular to the plume 

direction. The observer's line of sight did not include more than one plume at a time when 

multiple stacks are involved, and in any case the observer did make his observations with 

his line of sight perpendicular to the longer axis of such a set of multiple stacks (e.g., stub 

stacks on bag-houses). The observer did record the name of the plant, emission location, 

facility type, observer's name and affiliation, and the date on a field data sheet. The time, 

estimated distance to the emission location, approximate wind direction, estimated wind 

speed, description of the sky condition (presence and color of clouds), and plume 

background are recorded on the field data sheets at the time opacity readings are initiated 

and completed. Observations were made in fifteen-second intervals and recorded in 

increments of 5%. The Baghouse was observed for three one hour runs in conjunction 

with the Method 5/202 testing. 

The Clay Preparation Stack falls under subpart OOO. The regulations for subpart OOO 

require that the minimum distance between the observer and the emission source shall be 

fifteen (15) feet and that the duration of the Method 9 observations shall be one hour (ten 

6-minute averages) when determining compliance with opacity of stack emissions. 

31 
Visual Determination of Fugitive Emissions Method 22 (CD02) 

The sources evaluated were outdoors. The observer, Mr. Tommy Lotz, Jr. was-positioned 

within the 15 to 1320 feet from the source and where the sunlight was not directly shinning 

in his eyes. The Fugitive emissions from these sources were determined in compliance 

with Title 40, Section 60, Subpart OOO which required that the minimum test time be 75 

minutes, all sides being read, and that each side and the roof being observed for a period 

of 15 minutes each. 

32 
Entec Services, Inc 

16 D Commerce Ave. Hueytown, AL 35023 

STACK DRAWING & TRAVERSE POINT LOCATION 

Client: Boral Bricks Job No. 28162 

Source: DIFF Inlet Input By: Art Otero 

Type of Traverse: Velocity (V) or Particulate (P): P Port Type Nipple Port Diameter 6.0" 

Stack Diameter, inches: 71.5 Stack Area, Ft2: 27.883 

Stack Height, feet: 100 Number of Ports: 2 

Stack Properties: Inches Duct Diameters Length of Port, inches: 6.00 

132.0 1.85 Total Number of Traverse Points: 12 

960.0 13.43 Number of Points per diameter: 6 

Upstream Disturbance: 

Downstream Disturbance: 

71.5 INCHES 

Inside Stack Outside Nipple 

Point No. Inches Inches 

132.0 INCHES 

3,1 9.1 

2 10.4 16.4 

3 21.2 27.2 

4 50.3 56.3 

5 61.1 67.1 

6 68.4 74.4 

960.( 

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. 

qCHES 

33 
Entec Services, Inc 

16 D Commerce Ave. Hueytown, AL 35023 

STACK DRAWING & TRAVERSE POINT LOCATION 

Client: Boral Bricks Job No, 28162 

Source: DIFF Outlet Input By: Art Otero 

Type of Traverse: Velocity (V) or Particulate (P): P 

Stack Diameter, inches: 70 

Stack Height, feet: 75 

Stack Properties: Inches Duct Diameters 

Upstream Disturbance: 304.0 

Downstream Disturbance: 372.0 

4.34 

5.31 

Port Type Nipple 

Stack Area, Ft•: 

Number of Ports: 

Length of Port, inches: 

Total Number of Traverse Points; 

Number of Points per diameter: 

Port Diameter 

26.725 

2 

11.25 

20 

10 

.© 

304.(; .CNES 

Point No. 

Inside Stack Outside Nipple 

Inches Inches 

1.8 13.1 

2 5.7 17.0 

3 10.2 21.5 

4 15.8 27.1 

5 23.9 35.2 

6 46.1 57.3 

7 54.2 65.4 

8 59.8 71.0 

9 64.3 75.5 

10 68.2 79.4 

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. 

34 
Entec Services, Inc 

16 D Commerce Ave. Hueytown, AL 35023 

STACK DRAWING & TRAVERSE POINT LOCATION 

Client: Boral Bricks Job No. 28162 

Source: Clay Preparation Dust Collector Input By: Art Otero 

Type of Traverse: Velocity (V) or Particulate (P): P Port Type Nipple Port Diameter 6.0" 

Stack Diameter, inches: 43.5 Stack Area, Ft2: 10.321 

Staok Height, feet: 100 Number of Porte: 2 

Stack Properties: Inches Duct Diameters Length of Port, inches: 5,50 

24,0 0,55 Total Number of Traverse Points: 24 

265,5 6,10 Number of Points per diameter: 12 

Upstream Disturbance: 

Downstream Disturbance: 

43.5 INCHES 

Inside Stack Outside Nipple 

Point No. Inches Inches 

24.C NCHES 

265.5 NCHES 

1.0 *adjusted 6.5 

2 2.9 8.4 

3 5.1 10.6 

4 7.7 13.2 

5 10.9 16.4 

6 15.5 21.0 

7 28.0 33.5 

8 32.6 38.1 

9 35.8 41.3 

10 38.4 43.9 

11 40.6 46.1 

12 42.5 *adjusted 48.0 

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. 

35 
Method 5/202 Sami•l g Train 

Filter Exit Temperature 

(-248 F) 

•[Heated Filter, Filter] • Holder and Probe 

(-248 °F) 

L___ Temperature 

Sensors 

apmg• •ptng• 

#2 #3 

OOml OOm] 

H20 H20 

Impinger Exit Temperature 

(<68 F) 

Exhaust 

Temperature 

O Q Man°meter 

I'•'--- • 

36 
In-stack 

Filter 

Instrument Sampling Train 

EPA Method 6C 

Three Way Valve 

Heated 

Stainless 

Steel Probe 

System 

Calibration Gas Line 

Heated Teflon Line 

Communication Lines 

Flow Control 

Panel 

O0 

S02 

Data 

Acquisition 

System 

00• 

Air Sampling 

Analyzers 

/ 

Calibration 

Gases 

37 
Method 26A Sampling Train 

Filter Exit(>248 °TemperatureF) 

apmger 

#2 

100ml 

Impinger Exit Temperature 

(<68 F) 

aping [Impinge Jmoin£er 

#3 #4 !5 

3.1N 0.1N -250g 

laO• NaOE Silica Gel 

•1 •e •am 

Exhaust Ioooo•o•o ol • 

Controllers 

• 

Temperature 

38