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,

comEntec 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 127233337383940475359606467707178849091959810t102107111115116117121Field 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 239Executive 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 0Z0Detailed Test

ResultsEntec 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: 28162ENTEC 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

29.6160
!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
Y 0.978 Meter Correction

Factor 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 81.77.615.0 Impingers Weight Gain (Moisture) Silica Gel Impinger Weight Gain (Moisture) grams 88.313.515,0 grams

94.110.615.0 WlmpW•gO2 Oxygen Concentration,

dry basis 88.010.615.0 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)

0.192 468.2 F 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

91.5ENTEC 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%

10Entec 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
11ENTEC 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 AsPbarP•Cp
Y

Units Test Data 1 2

3
Military Time minutes Ftin. 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

12ENTEC 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%

13Entec 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

14ENTEC 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

AsebarP9Cp
Y&H@DnVmtmAHWimpWs•

CO•SO2 (sqrt/•P)av•

Units

Military Time minutes Ftin. Hg in. H20

in. Hz0 inches dcfF 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 74.10.99 45.36.817.03.061.1 1114-1216 6O 26.725 29.61 -0.22 0.84 1.018 1.753 0.310 31.696 77.80.87 44.87.417.03.062.3 0.378 0.402

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 0.9447.66.817.03.0

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

6O

29.61 -0.21 0.841.018 1.753 0.310 32.693 77.5 0.93 45.97.017.03.0 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

15ENTEC 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

16Entec 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

23452O2 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

17ENTEC 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•CpY

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 WirnpWs•O• 0.90 0.90 0.90 0.89 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 Fmg (sqrt ,•P),• 0.377 310.0 54.812.8 ts

mo + mi mb Avg. Sq. Rt. of Delta P Stack Temperature Total condensible

particulate

collected Total particulate

collected 0.376 309.154.412.6 0.379 308.6 65.5

0.377 309.2 58.211.0 7.6 mn mg

18ENTEC 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

19Entec 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

2345922202

2OENTEC 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

AsebarP•Cp
Y minutes Ftin. 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 74.57.29.0 Wimp

02C02 (sqrt '•P)av•

mo + ml- mb 0.0 1.219 79.911.113.8 mn Oxygen Concentration,

dry basis Carbon Dioxide Concentration,

dry basis Avg. Sq. Rt. of Delta P 0.0 1.239 83.04.48.5 Stack Temperature Total condensible

particulate

collected Total particulate

collected mgmg 0.01.225 79.17.610.4

21ENTEC 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%

22Sampling ProceduresProced 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

24moisture 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
25section 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.

26The 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. 27The 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 therinsing 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 29using 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

3oMoisture 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.

31Visual 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.

32Entec 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

33Entec 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

26.725211.252010

.© 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.

34Entec 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.

35Method 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'•'---

•

36In-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

37Method 26A

Sampling Train

Filter Exit(>248°TemperatureF)

apmger #2100ml 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