Exhaust Emissions

Sampling Boral Bricks,

Henderson.

TX Tunnel Kiln #1 and #2 Scrubber

Exhaust March 13, 2002 Armstrong Environmental,

Inc. Project W-2193-02

Report Prepared

For: David Johnson Boral Bricks, Inc. 100 Brickyard

Rd. Phenix City, AL 36869

Report Prepared

March 29, 2002 By: Armstrong Environmental,

Inc. 771.5 Sovereign

Row Dallas, Texas 75247 (214) 631-0021II.

III.

IV. TABLE

OF CONTENTS

Introduction Summard
Procedures Appendices

A. Calculation

Summaries

B. Analytical

Summaries

C. Field Data Sheets

D. Equipment

Calibrations Page

1

2-3

4

5-7

8 26

27 29

30 32I. INTRODUCTION

A series of tests was performed

on the exhaust of the scrubber

associated

with Tunnel Kilns #1 and #2 at the Boral Bricks, Inc. facilityin

Henderson,

TX on March 13, 2002. The purpose

of this test series was to determine

the exhaust emission

rate of Hydrogen Fluoride and Hydrogen

Chloride

in terms of lbs/hr. Testing followed

procedures

detailed

in Title 40: Code of Federal Regulations

(40:CFR). Sampling was performed

by Richard

Taylor and Tom Armstrong

of Arrnstrong Environmental, Inc. using an Apex Method

5 sampling

train. Three one hour test repetitions

were performed,

commencing

at 8:25 AM and ending at 11:55 AM. e•,..t,•,,,o[

/

•PresidentII. SUMMARY

A series of tests was performed

on the scrubber

exhaust associated

with Tunnel Kilns #1 and #2 at the Boral Bricks, Inc. facility in Henderson,

TX on March 13, 2002. Sampling was performed

following

procedures

detailed

in Title 40: Code of Federal Regulations.

Results of this test series are summarized

in Table 1. Results indicate

the following

emissions

rates:

HF, lbs/hr

5.119

4.543

3.637

4.433 HC1, lbs/hr

2.441

2.387

2.684

2.504SUMMARY OF EMISSIONS

TEST DATA

Table 1 Plant Bor.al Brick, Henderson,

TX Location Scrubber

Exhaust

Kilns #1 & #2 Operator T. Armstrong,

R. Taylor Test Date 13-Mar-02 Repetition 1 3

STACK GAS Temperature, F 348.5 352.9 356.6 Velocity, fps 44.16 43.84 43.81 Volume Flow, acfm 73872.2 73345.1 73300.7 scfm 44422.5 43910.7 43652.1 scfh 2665348 2634643 2619124 Moisture, % 6.70% 6.61% 6.69% C02, % 3.50 3.50 3.00 02, % 17.00 17.00 17.00

8:25 AM 9:28 AM 33.421 98.6441

9:40 AM 10:43 AM 33.539 100.1442 SAMPLE Start Time, hrs:min Finish Time, hrs:min Sample Volume,

scf Isokinetic Ratio, %

29.11 36.98974 5.118927 26.23 33.21349 4.54339 HYDROGEN FLUORIDE Sample Weight, mg Concentration, ppm Emissions, Ibs/hr

13.88 9.664195 2.440766 13.78 9.560984 2.386882 HYDROGEN CHLORIDE Sample Weight, mg Concentration, ppm Emissions,. Ibs/hr 10:50 AM 11:55 AM 32.968 99.02198

20.76 26.74261 3.636667

15.32 10.81365 2.683706III. PROCEDURES

The procedure

for emissions

sampling

followed

USEPA

test methods

as detailed

in Title 40: Code of Federal Regulations.

The following

methods

were used:
Method Title Sample and Velocity

Traverses

for Stationary

Sources

2 Determination

of Stack Gas Velocity

and Volumetric

Flow Rate (Type S Pitot Tube)

Gas Analysis

for CO2, 02, Excess Air and Dry Molecular

Weight

26A Determination

of Hydrogen

Halides and Halogens

Emissions

from Stationary Sources

02 and CO2 were determined

using FyRite Analyzers.

HF and HC1 sampling

was performed

for 2.5 minutes

at each of 24 points, 12 points per traverse, making a total run duration

of 60 minutes.

A schematic

of the sampling

location is shown in Appendix

C. The sampling

train was configured

as follows:
Glass Sampling

Nozzle Heated Glass Lined Probe Heated teflon filter Impinger #1 100 mls 0.1 N H2SO4 Impinger #2 100 mls 0.1 N H2SO4 Impinger #3 Empty Impinger #4 200 grams silica Gel

HF and HC1 analysis

was performed

on the solution

from the 1 st and 2nd impingers. Analysis was performed

using a Dionex 500DX IC/I-IPLC.

4EMISSION TEST SUMMARY

PLANT Boral Brick, Henderson,

TX DATE ]3-Mar-02 PLACE Scrubber Exhaust Kilns #1 & #2 RUN#

TEST DURATION

(MINUTES) NOZZLE DIAMETER (INCH.) METER COEFFICIENT

(Y) PITOT COEFFICIENT

(Cp) GAS METER VOL.(Cu.Ft.) BAROMETRIC PRESSURE 60 0.255 0.991 0.84 33,881 29.55 LIQUID COLLECTED

(mls) PARTICULATE WEIGHT (Front half mg) PARTICULATE WEIGHT (Back half mg) STATIC PRESSURE (in. H20) PERCENT C02 PERCENT 02 PERCENT CO

FOR CIRCULAR STACK STACK DIAMETER (inch): STACK AREA (Sq.Ft,) NOZZLE AREA (feet): FOR RECTANGULAR

STACK 71.5 STACK LENGTH(inchs): 27.883 STACK WIDTH(inchs): 0.000355 STACK AREA(Sq.Ft.):

ENTER THE STACK AREA SHOWN ABOVE:

27.883

FLOWS SAMPLED VOLUME (STD. CU.FT.): VOLUME OF WATER VAPOR (STD. CU.FT.): FRACTIONAL MOISTURE

CONTENT (%): DRY BASE: MOLECULAR WT. OF STACK GAS (DRY BASE): MOLECULAR WT. OF STACK GAS (WET BASE):

STACK PRESSURE

(inch Hg): STACK GAS VELOCITY (ft/sec.): ACTUAL STACK GAS FLOW RATE (ACFM): STANDARD STACK GAS FLOW RATE (SCFH):

33.4215 2.4006 0.0670 79.5000 29.2400 28.4868

29.5309 44.1561 73872.2056 2665347.98

ISOKINETIC RATIO (%): 98.6441 5100 -0.26 3.5170

POINTS STACK T. deg F DELTA P SQUAR D.P DELTA H

349 0.35 0.591608

0.70 2 349

0.36

0.6 0.72 3 350

0.35 0.591608

0.70 4 350

0.35 0.591608

0.70 5 350

0.36

0.6 0.72 6 350

0.37 0.608276

0.74 7 350

0.47 0.685565

0.95 8 350

0.46 0.678233

0.92 9 350

0.45 0.67082

0.90 10 351

0.43. 0.655744

0.86 11 341

0.36

0.6 0.72 12 338

0.22 0.469042

0.44 13 342

0.35 0.591608

0.70 14 352

0.37 0.608276

0.74 15 352

0.36

0.6 0.72 16 353

0.36

0.6 0.72 17 353

0.37 0.608276

0.74 18 355

0.37 0.608276

0.74 19 353

0.52 0.72111

1.00 20 353

0.55 0.74162

1.10 21 353

0.57 0.754983

1.10 22 353

0.53 0.728011

1.10 23 343

0.42 0.648074

0,84 24 325

0.25

0.5 0.50

348.54167 METER T. INLET

63 63 6363 6263 64 64 64 65 6566 65 66 67 67 68 69 7172 74 74 74 73 METER T. OUTLET

63 63 62 6160 60 60 60 6O 60 61 6162 62 62 62 63 63 64 65 66 6767 67

0.6272 0.7946

66.8750

62.5417 METER T. AVERAGE

64.7083 5EMISSION TEST SUMMARY

PLANT Boral Brick. Henderson,

TX DATE 13-Mar-02 PLACE Scrubber Exhaust Kilns #1 & #2 RUN# 2

TEST DURATION

(MINUTES) NOZZLE DIAMETER (INCH.) METER COEFFICIENT

(Y) PITOT COEFFICIENT

(Cp) GAS METER VOL.(Cu.Ft.) BAROMETRIC PRESSURE 60 0.255 0.991 0.84 34.634 29.55 LIQUID COLLECTED

(mls) PARTICULATE WEIGHT (Front half mg) PARTICULATE WEIGHT (Back half mg) STATIC PRESSURE (in. H20) PERCENT C02 PERCENT 02 PERCENT CO

FOR CIRCULAR STACK STACK DIAMETER (inch): STACK AREA (Sq.Ft.) NOZZLE AREA (feet): 71.5 27.883 0.000355

ENTER THE STACK AREA SHOWN ABOVE:

FOR RECTANGULAR

STACK STACK LENGTH(inches) STACK WIDTH(inches) STACK AREA (Sq.Ft.)

27.883

FLOWS SAMPLED VOLUME (STD. CU.FT.): VOLUME OF WATER VAPOR (STD. CU.FT.): FRACTIONAL MOISTURE

CONTENT (%): DRY BASE: MOLECULAR WT. OF STACK GAS (DRY BASE): MOLECULAR WT. OF STACK GAS (WET BASE):

STACK PRESSURE

(inch Hg): STACK GAS VELOCITY (ft/sec.): ACTUAL STACK GAS FLOW RATE (ACFM): STANDARD STACK GAS FLOW RATE (SCFH):

tSOKINETIC RATIO (%): 33.5389 2.3723 0.0661 79.5000 29.2400 28.4975

29.5294 43.8410 73345.0648 2634643.11

100.1442 50.400 -0.28 3.5170

POINTS STACK T. DELTA P SQUAR D.P degF

355

0.34 0.583095 2 356

0.35 0,591608 3 355

0.33 0.574456 4 355

0,33 0.574456 5 356

0.34 0.583095 6 356

0.36

0.6 7 356

0.47 0.685565 8 355

0.45 0.67082 9 355

0.44 0.663325 10 354

0.42 0.648074 11 352

0.37 0.608276 12 321

0.26 0.509902 13 349

0.35 0.591608 14 356

0,35 0.591608 15 357

0.35 0.591608 16 357

0.34 0.583095 17 357

0.36

0.6 18 357

0.37 0.608276 19 357

0.53 0.728011 20 358

0.55 0.74162 21 357

0.55 0.74162 22 357

0,53 0.728011 23 357

0.41 0.640312 24 325

0.22 0.469042

DELTA H

0,69 0.70 0.68 0.71 0.73 0.77 1.00 0.97 0.95 0,90 0.80 0.56 0,75 0.75 0,75 0,73 0.77 0.80 1.10 1,20 .20 1.10 0.88 0.47 METER T. INLET

69 74 74 77787979 8O7978787775 757778 8O79797878777777 METER T. OUTLET

6768 68 69 71717273 7273 74 7272 72 7172 73 7474 74 75 73 7373

352.91667 0.6211

0.8317

77.1667

71.9167 METER T. AVERAGE

74.5417EMISSION TEST SUMMARY

PLANT Boral Brick, Henderson,

TX DATE 13.Mar-02 PLACE Scrubber Exhaust Kilns #1 & #2 RUN# 3

TEST DURATION

(MINUTES) NOZZLE DIAMETER (INCH.) METER COEFFICIENT

(Y) PITOT COEFFICIENT

(Cp) GAS METER VOL.(Cu.Ft.) BAROMETRIC PRESSURE 60 0,255 0,991 0.84 34,62 29.55 LIQUID COLLECTED

(mls) PARTICULATE WEIGHT (Front half rag) PARTICULATE WEIGHT (Back half mg) STATIC PRESSURE (in. H20) PERCENT C02 PERCENT 02 PERCENT CO

FOR CIRCULAR STACK STACK DIAMETER (inch): STACK AREA (Sq.Ft.) NOZZLE AREA (feet): FOR RECTANGULAR

STACK 71.5 STACK LENGTH(inchs): 27.883 STACK WIDTH(inchs): 0.000355 STACK AREA(Sq.Ft.):

ENTER THE STACK AREA SHOWN ABOVE:

27.883

FLOWS SAMPLED VOLUME (STD. CU.FT.): VOLUME OF WATER VAPOR (STD. CU.FT.): FRACTIONAL MOISTURE CONTENT (%): DRY BASE: MOLECULAR WT. OF STACK GAS (DRY BASE): MOLECULAR WT. OF STACK GAS (WET BASE):

STACK PRESSURE

(inch Hg): STACK GAS VELOCITY (ft/sec.): ACTUAL STACK GAS FLOW RATE (ACFM): STANDARD STACK GAS FLOW RATE (SCFH):

ISOKINETtC RATIO (%): 32.9677 2.3629 0.0669 80.0000 29.1600 28.4136

29.5316 43.8145 73300.7331 2619124.12

99.0220 50.200 -0,253 170

POINTS STACK T. DELTA P SQUAR D.P deg F

353

0.33 0.574456 2 359

0.33 0.574456 3 359

0.34 0.583095 4 358

0.33 0.574456 5 358

0.33 0.574456 6 359

0.36

0.6 7 358

0.46 0.678233 8 359

0.45 0.67082 9 359

0.42 0.648074 10 359

0.40 0.632456 11 354

0.37 0.608276 12 337

0.25

0.5 13 355

0.35 0.591608 14 359

0.35 0.591608 15 360

0.35 0.591608 16 360

0.36

0.6 17 360

0.37 0.608276 18 360

0.37 0.608276 ]9 359

0.53 0.728011 20 360

0.56 0.748331 21 358

0.55 0.74162 22 360

0.53 0.728011 23 355

0.41 0.640312 24 340

0.20 0.447214

356.58333 0.6185 DELTA H

0.71 0.71 0.73 0.71 0.71 0.77 1.00 0.97 0.90 0.86 0,80 0.54 0,75 0.75 0.75 0,77 0,80 0.80 1.10 t.20 1.20 1.10 0.90 0.43

0.8317 METER T. INLET

7479 8O 8O 8O 8182 83 85 86 86 86 86 89 9O 9]919190 92 92 92 92 91

86.2083 METER T. OUTLET

7475 75 7575 76767778 79 79 8O 83 83 85 85 85 86 85 86 86 86 8787

80.9583 METER T. AVERAGE

83.5833