Exhaust Emissions

Sampling Acme Brick Company,

Malakoff,

TX Tunnel Kiln Scrubber

Inlet and Exhaust

(EPN 25) Rotary Kiln Scrubber

Exhaust

(EPN 58) TNRCC Permit No. 45073 March 26 April 2, 2002 Armstrong Environmental,

Inc. Project W-2195-02

Report Prepared

For: Mike O'Conner Acme Brick 2821 West Seventh

Street Ft. Worth, TX 76107

Report Prepared

April 5, 2002 By: Armstrong Environmental,

Inc. 7715 Sovereign

Row Dallas, Texas 75247 (214) 631-0021TABLE OF CONTENTS

I. Introduction II. Summary III. Procedures IV. Appendices A. Calculation

Summaries B. Continuous

Emissions

Monitor

Summaries C. Analytical

Summaries D. Field Data Sheets E. Equipment

Calibrations F. Standard

Gas Certit]cations G. Production

Data H. Resumes

and Certifications I. TNRCC

Method

Approval Page12-67-13

14-2223-147 148-239 240-260 261-273 274-285 286-295 296-301 302-304I. INTRODUCTION A series of tests was performed

on the scrubber

inlet and exhaust associated

with Tunnel Kiln B (EPN 25) and on the scrubber

exhaust associated

with the Rotary Kiln (EPN 58) at the Acme Brick facility in Malakoff,

TX on March 26 April 2, 2002. The purpose

of this test series was to determine

the following

parameters:
EPN 25 B Kiln Scrubber Exhaust B Kiln Scrubber

Inlet

PM, CO, NOx, SO2, VOC, HF, HC1, Opacity HF, HC1 EPN 58 Rotary Kiln Wet PM, CO, NOx, SO2, VOC, Scrubber HF, HC1, Opacity EPN 58 Rotary Kiln Wet

Front HalfPM,

Opacity Scrubber

TNRCC

Permit 45073 Special Condition

5, 11, 12 TNRCC Permit 45073 Special Condition

5 TNRCC Permit 45073 Special Conditions

5, 11, 12 NSPS Subpart UUU Testing followed

procedures

detailed

in Title 40: Code of Federal Regulations

(40:CFR). Sampling was performed

by Richard

Taylor, Jerry Salinas, Bart Tarbell and Tom Armstrong of Armstrong

Environmental,

Inc. using two Apex Method

5 sampling

trains, a ThermoEnvironmental 42CLS continuous

NOx analyzer,

a Western

Research

721M continuous SO2 analyzer,

a Fuji 3300 continuous

CO analyzer,

and a ThermoEnvironmental Model 51 continuous

FID analyzer. Sampling was performed

according

to the following

schedule:
EPN 25

3/26/02 10:53 AM

4:00 PM EPN 58

3/27/02 11:30 AM

4:39 PM EPN 58

3/28/02 9:40 AM

12:42 PM EPN 25 (Opacity)

4/1/02 10:10 AM

1:36 PM EPN 58 (Opacity)

4/2/02 2:35 PM

3:35 PMII. SUMMARY A series of tests was performed

on the scrubber

inlet and exhaust associated

with Tunnel Kiln B, and the scrubber

exhaust associated

with the Rotary Kiln at the Acme Brick facility in Malakoff,

TX March 26 April 2, 2002. Sampling was performed

following

procedures

detailed

in Title 40: Code of Federal Regulations. Results of this test series are summarized

in Tables

3. Results indicate

the following

emissions

rates for EPN 25:

PM; lbs/hr

3.228

3.891

4.329 10.38 CO, lbs/hr

20.43

20.13

20.74

20.43

14.32 NOx, Ibs/hr

1.337

1.378

1.328

1.348

4.18 VOC, lbs/hr

1.697

2.092

1.535

1.775

0.29 SO2• Ibslhr

14.74

13.37

12.74

13•62

5.59 Exhaust HF,

0.158

0.140

0.128

0ii42

0.44 lbs/hr Inlet HF,

4.470 4.235

4497 lbs/hr 96.97 Scrubber Efficiency, % Exhaust HC1, lbs/hr Inlet HC1,lbs/hr Scrubber Efficiency,Opacity, Highest 6 min. Average % 4.787 96.47 97.07 2.098 1.845 2.252 2.110 6.84 12.56 1.46 1.04

2.0672.027

96i83

901.42 2i0032:129 0 6•47

30 3.96 2.15

10
Results indicate

this source to be over the limits given in Permit 45073 for CO, VOC, SO2, HC1, and HC1 removal

efficiency. Results indicate the following

emission

rates for EPN 58:SUMMARY OF EMISSIONS

TEST DATA Table: 2 Plant: Acme Brick, Malakoff,

TX Location Kiln Scrubber

!•le t Operator: J. Salinas,

B. Tarbell Test Date 26-Mar.02 Repetition 1 STACK GAS Temperature, F .339.5 338.7 Velocity, fps 43.27 45.68 Volume Flow, acfm 28042.8 29600.6 scfm 17550.2 18322.3 scfh 1053013 1099340 Moisture, % 5.11% 6.25% CO2, % 2.00 2.50 02, % 17.00 17.50 SAMPLE Start Time, hrs:min Finish Time, hrs:min Sample Volume,

scf Isokinetic Ratio, % 10:53 AM 12:15 PM 39.234 97.65202

12:47 PM 2:05 PM 41.035 97.83113 HYDROGEN FLUORIDE Sample Weight, mg Concentration, ppm Emissions, Ibs/hr 75.53 81.75732 4.469964 81.03 83.86099 4.786695 HYDROGEN CHLORIDE Sample Weight, mg Concentration, ppm Emissions, Ibs/hr 38.06 22.57424 ,2.252441 35.71 20.25075 2.109501 3
350.342.99 27857:7 17000.1 1020006,6.21%2,00

2:43 PM 4:00 PM 38.829 99.77242
73.11 79.9626 4.234803
34.99 20.96965 2.026751

5SUMMARY OF EMISSIONS

TEST DATA TablePlant Acme Brick, Malakoff, TX Location Kiln Scrubber EXhaU?• Operator R. Taylor, T. Armstrong Test Date 26-Mar-02 Repetition 2 STACK GAS Temperature, F 344.8

338.5 Velocity, fps 41.15

40.45 Volume Flow, acfm .,29748,0

.29243.2 scfm 18318,0

18073,8 scfh 1099080

1084428 M•)isture, % 6.48%

.6.87% C02, % 2.00

2.50 02, % 17.00

17.00 SAMPLE Start Time, hrs:min 10:53 AM

12:47 PM Finish Time, hrs:min 12:15 PM

2:05 PM Sample Volume, scf

38.128

37.215 Isokinetic Ratio, %

101.1588

100.0715 PARTICULATE Front Half Sample Weight, mg 14.99

14.69 Concentration, gr/scf

0.006066

0.006091 Emissions, Ibs/hr 0,952796

0.943873 Back Half Sample Weight, mg 35.79

45.87 Concentration, gr/scf

0.014484

0.019019 Emissions, Ibs/hr 2.274887

2,947273 Total Particulate,

Ibs/hr

3.227683

3.891146 CARBON MONOXIDE Concentration, ppm 255.69

255.4 Emissions, Ibs/hr 20.42748

20.1323 NITROGEN OXIDE AS NO2 Concentration, ppm 10.19

10.64 Emissions, Ibs/hr 1.337442

1.377888 VOC AS Carbon Concentration, ppm as C3H8 WET

15.45

19.22 Concentration, ppm as C, DRY

49.56009

61.91177 Emissions, Ibs/hr 1.6969

2.091553 SULFUR DIOXIDE Concentration, ppm 80.73

74.19 Emissions, Ibs/hr 14.74205

13.36718 HYDROGEN FLUORIDE Sample Weight, mg 2.49

2.18 Concentration, ppm

2.772362

2.487733 Emissions, Ibs/hr O. 158206

O. 140071 HYDROGEN CHLORIDE Sample Weight, mg 33.01

28.71 Concentration, ppm

20.14383

17.95344 Emissions, Ibs/hr 2.097867

1.844825 3
333.140.57 29328.2 18299.8 10979876.62%2.0017.00
2:43 PM 4:00 PM 37.668 100.0386

21.07 0.008631 1.35425
46.29 0.018962 2.975237 4.329488
259.91 20.74398
10.13 1.328246
13.97 44.87943 1.535111
69.83 12.73894
1.99 2.243605 0.127905
32.16 19.8658 2.066855III. 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 1 Sample and Velocity

Traverses

for Stationary

Sources 2 Determination

of Stack Gas Velocity

and Volumetric

Flow Rate (Type S Pitot Tube) 3 Gas Analysis

for CO2, 02, Excess Air and Dry Molecular

Weight 5 Determination

of Particulate

Emissions

from Stationary

Sources 6C Determination

of Sulfur Dioxide

Emissions

from Stationary

Sources (Instrumental Analyzer

Procedure) 7E Determination

of Nitrogen

Oxides Emissions

from Stationary

Sources (Instrumental Analyzer

Procedure) 9 Visual Determination

of the Opacity Of Emissions

from Stationary Sources 10 Determination

of Carbon Monoxide

Emissions

from Stationary

Sources 25A Determination

of Total Gaseous

Organic

Concentration

using a Flame Ionization Analyzer 26A Determination

of Hydrogen

Halides and Halogens

Emissions

from Stationary Sources 02 and CO2 were determined

using FyRite Analyzers. PM. HF and HC1 sampling

was performed

on B Kiln scrubber

exhaust

for 6 minutes

at each of 12 points, 6 points per traverse,

malting a total run duration

of 72 minutes.

A schematic Of the sampling

location

is shown in Figure 1. The sampling

train was configured as follows:

Glass Sampling

Nozzle Heated Glass Lined Probe Heated teflon filter Impinger #1 200 mls H20 Impinger #2 100 mls 0.1 N H2SO4 Impinger #3 100 mls 0.1 N H2SO4