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) 631-0021 
TABLE 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 

Page 

1 

2-6 

7-13 

14-22 

23-147 

148-239 

240-260 

261-273 

274-285 

286-295 

296-301 

302-304 
I. INTRODUCTION 

A series of tests was performed on the scrubber inlet and exhaust associated with Tunnel Kiln 

the Acme 

B (EPN 25) and on the scrubber exhaust associated with the Rotary Kiln (EPN 58) at 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 PM 
II. 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 

2.067 

2.027 

96i83 90 

2i003 1.42 

2:129 

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 

350.3 

42.99 

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 

5 
SUMMARY OF EMISSIONS TEST DATA 

Table 

Plant 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 

333.1 

40.57 

29328.2 

18299.8 

1097987 

6.62% 

2.00 

17.00 

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 

2.066855 
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 

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