Final Test Report 

for

BSCP-Kiln Emission Test #2673

Based on information and belief formed I have reviewed all testing details and 

after reasonable inquiry, I certify that results in this test report and hereby 

the statements and information in this certify that the test report is authentic 

test report are true, accurate, and and accurate.

complete.

/ /

Permitted Facility Representative / Testing Company Representative / 

Name: Bradley Belden Name James E. Phillippi, QSTI

Title: Corportate Manager-Occupational Title: Senior Project Manager

Company: Belden Brick Company: Blue Mountain Environmental 

Sign 10/6/2011 Sign Date: 9/15/2011

Page 1 of 11
BSCP-Kiln Emission Test #2673

10/6/2011

Facility Testing Company:

The Belden Brick Company Blue Mountain Environmental Management 

690 Dover Rd NE 1191 Pittsburgh Road

Sugarcreek OH 44681 Valencia PA 16059

Contact Bradley Belden Contact James Phillippi

Phone: 330-456-0031 Phone: 724-898-4500

Fax: 330-456-2694 Fax: 724-898-2908

Email: bradley.belden@beldenbrick.com Email: jphillippi@bluemountainusa.com

Industry/SCC/NAIS: 327121 AFS #: FRS #: 110000741859

Air Permit Number: Permitted Source 

06-79-000118 P301 Kiln Outlet

Permitted Maximum Process Max. Normal Operation Process Target Process Test Rate

13.78 7.06 7.06

SCC / Description:30500311 Industrial Processes - Mineral Products - Brick Manufacture - Curing and Firing:

Gas-fired Tunnel Kilns 

The following state and federal regulations that apply to the proposed testing:

Regulation Description Compound Limit Unit

Section 114 of the Clean Air Act 0

Description of the source (including control equipment). Please see the attachments for source

or

Belden Brick Plant 3 produces construction grade bricks. Plant 3 has one Kiln. The process begins when a 

clay/shale material is mined from the ground and processed through a primary crusher. This crushed raw 

material is transferred via conveyor to a storage building. The material is processed through a secondary 

crusher followed by particle sizing with a series of screens. The properly sized material is stored in a bin until it 

is metered into the plant. Once in the plant, the processed material is molded into the shape of a brick, dried on 

a tray, and loaded onto a kiln car. The kiln car is moved into a kiln where it is fired with natural gas at various 

temperatures depending on the desired product and the structure of the unit. After firing is completed, the brick

is cooled before being unloaded and packaged.

Sampling Location Information:

Round

Duct Rect. Duct Equiv. Distance from Distance from Number of Min.Travers 

Location Diam. Length /Width Diam upstream dist. downstream dist. Traverse Ports Points

Outlet of 46.5 0 0 0 144 432 2 12

Control 

Test Parameter Information:

Target Test Number of Test Run Sample 

Location Parameter Method Duration Points Comments

Outlet of Flowrate Method 1 - 4 3 60 0

Page 2 of 11
BSCP-Kiln Emission Test #2673

10/6/2011

 process flow diagram:

Outlet of % H2O Method 1 - 4 3 60 0

Control 

Outlet of Chlorine Method 26A 3 60 0

Control 

Outlet of Hydrogen Fluoride Method 26A 3 60 0

Control 

Outlet of Hydrogen Chloride Method 26A 3 60 0

Control 

Outlet of Selenium Method 29 3 60 0

Control 

Outlet of Arsenic Method 29 3 60 0

Control 

Outlet of Antimony Method 29 3 60 0

Control 

Outlet of Beryllium Method 29 3 60 0

Control 

Outlet of Cadmium Method 29 3 60 0

Control 

Outlet of Chromium Method 29 3 60 0

Control 

Outlet of Cobalt Method 29 3 60 0

Control 

Outlet of Lead Method 29 3 60 0

Control 

Outlet of Mercury Method 29 3 60 0

Control 

Outlet of Filterable Particulate Method 29 3 60 0

Control 

Outlet of Nickel Method 29 3 60 0

Control 

Outlet of Manganese Method 29 3 60 0

Control 

Outlet of O2 Method 3A O2 3 60 0

Control 

Outlet of Filterable Particulate Method 5 3 60 0

Control 

The following describes any modifications and/or deviations to the applicable test 

methods. If alternative methods were requested, see the attachments for 

documentation of request AND approval, including dates.

None

Page 3 of 11
BSCP-Kiln Emission Test #2673

10/6/2011

Sampling / Stack Data Results 

Location Outlet of Control Device - Method 26A

Average

Run Number 1 2 3

Test Date 7/25/2011 7/25/2011 7/25/2011

Run Start Time 12:07:00 PM 1:23:00 2:44:00 PM

Run Finish Time 1:11:00 PM 2:23:00 3:43:00 PM

Net Run Time, minutes 60 60 60

Dry Gas Meter Volume Sampled, dscf 51.091 50.357 50.006 50.485

Moisture Content of Stack Gas, % 6.22 5.68 7.10 6.333

Moisture Saturation at Stack Gas Temperature, % 100.00 100.00 100.00 100.000

Carbon Dioxide, % 2.3 2.4 2.4 2.367

Oxygen, % 17 16.8 16.8 16.867

Average Stack Gas Temperature, °F 380.33 375.00 395.58 383.637

Dry Volumetric Flow Rate, dry scfm 17,516.8 17,419.5 17,036.7 17,324.333

Actual Wet Volumetric Flue Gas Flow Rate, acfm 30,284.4 29,753.7 30,376.4 30,138.167

Percent Isokinetic of Sampling Rate, % 99.5 98.6 100.1 99.400

F-Factor, dscfm/MMBtu @ %O2 0 0 0 0.000

Fw 0 0 0 0.000

Fc 0 0 0 0.000

Page 4 of 11
BSCP-Kiln Emission Test #2673

10/6/2011

Location Outlet of Control Device - Method 29

Average

Run Number

Test Date

Run Start Time

Run Finish Time

Net Run Time, minutes

Dry Gas Meter Volume Sampled, dscf

Moisture Content of Stack Gas, %

Moisture Saturation at Stack Gas Temperature, %

Carbon Dioxide, %

Oxygen, %

Average Stack Gas Temperature, °F

Dry Volumetric Flow Rate, dry scfm

Actual Wet Volumetric Flue Gas Flow Rate, acfm

Percent Isokinetic of Sampling Rate, %

F-Factor, dscfm/MMBtu @ %O2

Fw

Fc

Page 5 of 11
BSCP-Kiln Emission Test #2673

10/6/2011

Emissions Summary

Location: Outlet of Control Device - Method 26A

Compound: Chlorine

Average

RunNumber 1 2 3

Mass_mg 1.2 1.2 1.2 1.20E+00

Eg/hr 2.47E+01 2.49E+01 2.45E+01 2.47E+01

ppm 2.81E-01 2.86E-01 2.88E-01 2.85E-01

ppm@7%O2 1.00E+00 9.70E-01 9.76E-01 9.82E-01

Compound: Hydrogen Chloride

Average

RunNumber 1 2 3

Mass_mg 3.9 5 3 3.97E+00

Eg/hr 8.02E+01 1.04E+02 6.13E+01 8.18E+01

ppm 1.78E+00 2.31E+00 1.40E+00 1.83E+00

ppm@7%O2 6.34E+00 7.83E+00 4.75E+00 6.31E+00

Compound: Hydrogen Fluoride

Average

RunNumber 1 2 3

Mass_mg 65 76 54 6.50E+01

Eg/hr 1.34E+03 1.58E+03 1.10E+03 1.34E+03

ppm 5.40E+01 6.41E+01 4.58E+01 5.46E+01

ppm@7%O2 1.92E+02 2.17E+02 1.55E+02 1.88E+02

Location: Outlet of Control Device - Method 29

Compound: Antimony

Average

RunNumber 1 2 3

Mass_mg 0.0012 0.0012 0.0012 1.20E-03

Eg/hr 2.46E-02 2.48E-02 2.47E-02 2.47E-02

mg/dscm 8.47E-04 8.57E-04 8.36E-04 8.47E-04

mg/dscm@7%O2 2.87E-03 3.05E-03 2.98E-03 2.97E-03

Compound: Arsenic

Average

RunNumber 1 2 3

Mass_mg 0.0012 0.0012 0.0012 1.20E-03

Eg/hr 2.46E-02 2.48E-02 2.47E-02 2.47E-02

mg/dscm 8.47E-04 8.57E-04 8.36E-04 8.47E-04

mg/dscm@7%O2 2.87E-03 3.05E-03 2.98E-03 2.97E-03

Compound: Beryllium

Average

RunNumber 1 2 3

Mass_mg 0.0003 0.0003 0.0003 3.00E-04

Eg/hr 6.14E-03 6.21E-03 6.17E-03 6.17E-03

mg/dscm 2.12E-04 2.14E-04 2.09E-04 2.12E-04

mg/dscm@7%O2 7.19E-04 7.63E-04 7.45E-04 7.42E-04

Page 6 of 11
BSCP-Kiln Emission Test #2673

10/6/2011

Compound: Cadmium

Average

RunNumber 1 2 3

Mass_mg 0.00044 0.00108 0.00044 6.53E-04

Eg/hr 9.01E-03 2.23E-02 9.06E-03 1.35E-02

mg/dscm 3.11E-04 7.71E-04 3.07E-04 4.63E-04

mg/dscm@7%O2 1.05E-03 2.75E-03 1.09E-03 1.63E-03

Compound: Chromium

Average

RunNumber 1 2 3

Mass_mg 0.01433 0.01124 0.00754 1.10E-02

Eg/hr 2.93E-01 2.33E-01 1.55E-01 2.27E-01

mg/dscm 1.01E-02 8.03E-03 5.25E-03 7.79E-03

mg/dscm@7%O2 3.42E-02 2.86E-02 1.87E-02 2.72E-02

Compound: Cobalt

Average

RunNumber 1 2 3

Mass_mg 0.00093 0.00219 0.00478 2.63E-03

Eg/hr 1.90E-02 4.53E-02 9.84E-02 5.42E-02

mg/dscm 6.57E-04 1.56E-03 3.33E-03 1.85E-03

mg/dscm@7%O2 2.23E-03 5.56E-03 1.19E-02 6.56E-03

Compound: Filterable Particulate

Average

RunNumber 1 2 3

Mass_mg 27.55 32.85 23.1 2.78E+01

Eg/hr 5.64E+02 6.80E+02 4.75E+02 5.73E+02

mg/dscm 1.95E+01 2.35E+01 1.61E+01 1.97E+01

mg/dscm@7%O2 6.61E+01 8.38E+01 5.74E+01 6.91E+01

Compound: Lead

Average

RunNumber 1 2 3

Mass_mg 0.00874 0.01003 0.00675 8.51E-03

Eg/hr 1.79E-01 2.08E-01 1.39E-01 1.75E-01

mg/dscm 6.17E-03 7.16E-03 4.70E-03 6.01E-03

mg/dscm@7%O2 2.09E-02 2.55E-02 1.68E-02 2.11E-02

Compound: Manganese

Average

RunNumber 1 2 3

Mass_mg 0.0386 0.01679 0.01632 2.39E-02

Eg/hr 7.90E-01 3.47E-01 3.36E-01 4.91E-01

mg/dscm 2.73E-02 1.20E-02 1.14E-02 1.69E-02

mg/dscm@7%O2 9.26E-02 4.28E-02 4.06E-02 5.87E-02

Compound: Mercury

Average

RunNumber 1 2 3

Mass_mg 0.014179 0.012881 0.015356 1.41E-02

Eg/hr 2.90E-01 2.67E-01 3.16E-01 2.91E-01

Page 7 of 11
BSCP-Kiln Emission Test #2673

10/6/2011

mg/dscm 1.00E-02 9.20E-03 1.07E-02 9.97E-03

mg/dscm@7%O2 3.39E-02 3.28E-02 3.81E-02 3.49E-02

Compound: Nickel

Average

RunNumber 1 2 3

Mass_mg 0.01688 0.00913 0.00966 1.19E-02

Eg/hr 3.46E-01 1.89E-01 1.99E-01 2.45E-01

mg/dscm 1.19E-02 6.52E-03 6.73E-03 8.38E-03

mg/dscm@7%O2 4.03E-02 2.32E-02 2.40E-02 2.92E-02

Compound: Selenium

Average

RunNumber 1 2 3

Mass_mg 0.0217 0.0206 0.0364 2.62E-02

Eg/hr 4.44E-01 4.26E-01 7.49E-01 5.40E-01

mg/dscm 1.53E-02 1.47E-02 2.54E-02 1.85E-02

mg/dscm@7%O2 5.19E-02 5.24E-02 9.05E-02 6.49E-02

Page 8 of 11
BSCP-Kiln Emission Test #2673

10/6/2011

Process Run Data

Target

Run Name Value UOM Value Comments

1 Brick Produced (7/25/2011) 0 Tons/hr 7.06

1 Brick Produced (7/26/2011) 0 Tons/hr 7.06

APCD Run Data

Target

Run Name Value UOM Value Comments

1 DRY SCRUBBER 0 lime feed 0

1 BAGHOUSE 0 pressure drop 0

Process Lab Run Data

Run Name Value UOM Comments

1 None 0

Page 9 of 11
BSCP-Kiln Emission Test #2673

10/6/2011

Sampling / Stack Data Results Detail

Location Outlet of Control Device - Method 26A

Average

Run Number 1 2 3

Test Date 7/25/2011 7/25/2011 7/25/2011

Run Start Time 12:07:00 PM 1:23:00 PM 2:44:00 PM

Run Finish Time 1:11:00 PM 2:23:00 PM 3:43:00 PM

Net Traversing Points 12 12 12

Net Run Time, minutes 60 60 60

Nozzle Diameter, inches 0.325 0.325 0.325 0.325

Pitot Tube Coefficient 0.84 0.84 0.84 0.840

Dry Gas Meter Calibration Factor 1.008 1.008 1.008 1.008

Barometric Pressure, inches of Mercury 29.4 29.4 29.3 29.367

Average Orifice Meter Differential, inches H2O 2.71 2.62 2.63 2.653

Dry Gas Meter Volume Sampled, cubic feet 54.118 53.124 53.265 53.502

Average Dry Gas Meter Temperature, °F 97.71 95.33 98.83 97.290

Dry Gas Meter Volume Sampled, dscf 51.091 50.357 50.006 50.485

Total Moisture Liquid collected, g 72.1 64.3 81.2 72.533

Volume of Water Vapor, standard cubic feet 3.39 3.03 3.82 3.413

Moisture Content of Stack Gas, % 6.22 5.68 7.10 6.333

Moisture Saturation at Stack Gas Temperature, % 100.00 100.00 100.00 100.000

Dry Mole Fraction 0.9378 0.9432 0.929 0.937

Carbon Dioxide, % 2.3 2.4 2.4 2.367

Oxygen, % 17 16.8 16.8 16.867

Carbon Monoxide & Nitrogen, % 80.7 80.8 80.8 80.767

Fuel Factor 1.70 1.71 1.71

Dry Molecular Weight, lb/lb-Mole 29.05 29.06 29.06 29.057

Wet Molecular weight, lb/lb-Mole 28.36 28.43 28.27 28.353

Flue Gas Static Pressure, inches of H2O -0.35 -0.35 -0.35 -0.350

Absolute Flue Gas Pressure, inches of Mercury 29.37 29.37 29.27 29.337

Average Stack Gas Temperature, °F 380.33 375.00 395.58 383.637

Average Velocity Head, inches of H2O 0.3521234271 0.34280287 0.345625616 0.347

96271 5134762 21152

Average Stack Gas Velocity, feet/second 42.80 42.05 42.93 42.593

Stack Cross-Sectional Area, square feet 11.793 11.793 11.793 11.793

Dry Volumetric Flow Rate, dry scfm 17,516.8 17,419.5 17,036.7 17,324.333

Actual Wet Volumetric Flue Gas Flow Rate, acfm 30,284.4 29,753.7 30,376.4 30,138.167

Percent Isokinetic of Sampling Rate, % 99.5 98.6 100.1 99.400

Percent Excess Air, % 394.9 370.8 370.8 378.833

F-Factor, dscfm/MMBtu @ %O2 0 0 0 0.000

Round Duct Diameter, inches 46.5 46.5 46.5

Rectangular Duct Width, inches 0 0 0

Rectangular Duct Length, inches 0 0 0

Fw 0 0 0 0.000

Fc 0 0 0 0.000

Page 10 of 11
BSCP-Kiln Emission Test #2673

10/6/2011

Location Outlet of Control Device - Method 29

Average

Run Number

Test Date

Run Start Time

Run Finish Time

Net Traversing Points

Net Run Time, minutes

Nozzle Diameter, inches

Pitot Tube Coefficient

Dry Gas Meter Calibration Factor

Barometric Pressure, inches of Mercury

Average Orifice Meter Differential, inches H2O

Dry Gas Meter Volume Sampled, cubic feet

Average Dry Gas Meter Temperature, °F

Dry Gas Meter Volume Sampled, dscf

Total Moisture Liquid collected, g

Volume of Water Vapor, standard cubic feet

Moisture Content of Stack Gas, %

Moisture Saturation at Stack Gas Temperature, %

Dry Mole Fraction

Carbon Dioxide, %

Oxygen, %

Carbon Monoxide & Nitrogen, %

Fuel Factor

Dry Molecular Weight, lb/lb-Mole

Wet Molecular weight, lb/lb-Mole

Flue Gas Static Pressure, inches of H2O

Absolute Flue Gas Pressure, inches of Mercury

Average Stack Gas Temperature, °F

Average Velocity Head, inches of H2O

Average Stack Gas Velocity, feet/second

Stack Cross-Sectional Area, square feet

Dry Volumetric Flow Rate, dry scfm

Actual Wet Volumetric Flue Gas Flow Rate, acfm

Percent Isokinetic of Sampling Rate, %

Percent Excess Air, %

F-Factor, dscfm/MMBtu @ %O2

Round Duct Diameter, inches

Rectangular Duct Width, inches

Rectangular Duct Length, inches

Fw

Fc

Page 11 of 11