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) 631-0021 
II. 

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 32 
I. 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[ / 

•President 
II. 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 2.504 
SUMMARY 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 

2.683706 
III. 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. 

4 

EMISSION 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 

51 

0 

0 

-0.26 

3.5 

17 

0 

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 

63 

63 

62 

63 

64 

64 

64 

65 

65 

66 

65 

66 

67 

67 

68 

69 

71 

72 

74 

74 

74 

73 

METER T. 

OUTLET 

63 

63 

62 

61 

60 

60 

60 

60 

6O 

60 

61 

61 

62 

62 

62 

62 

63 

63 

64 

65 

66 

67 

67 

67 

0.6272 0.7946 66.8750 62.5417 

METER T. 

AVERAGE 

64.7083 

5 
EMISSION 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 

50.4 

0 

0 

-0.28 

3.5 

17 

0 

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 

77 

78 

79 

79 

8O 

79 

78 

78 

77 

75 

75 

77 

78 

8O 

79 

79 

78 

78 

77 

77 

77 

METER T. 

OUTLET 

67 

68 

68 

69 

71 

71 

72 

73 

72 

73 

74 

72 

72 

72 

71 

72 

73 

74 

74 

74 

75 

73 

73 

73 

352.91667 0.6211 0.8317 77.1667 71.9167 

METER T. 

AVERAGE 

74.5417 
EMISSION 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 

50.2 

0 

0 

-0,25 

3 

17 

0 

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 

74 

79 

8O 

8O 

8O 

81 

82 

83 

85 

86 

86 

86 

86 

89 

9O 

9] 

91 

91 

90 

92 

92 

92 

92 

91 

86.2083 

METER T. 

OUTLET 

74 

75 

75 

75 

75 

76 

76 

77 

78 

79 

79 

8O 

83 

83 

85 

85 

85 

86 

85 

86 

86 

86 

87 

87 

80.9583 

METER T. 

AVERAGE 

83.5833