ENTEC Services 

Pollution Control System Evaluation and Source Emissions Testing 

Cherokee Brick and Tile 

Macon, Georgia 

Compliance Emissions Testing 

No. 1 and No. 2 Kilns Dry Lime Absorber Stack 

December 13, 2006 

Entec Project No.: 26180 

16-D Commerce Avenue Hueytown, Alabama 35023 Phone: (205) 491-6676 Fax (205) 491-6614 

www.entecservices.com 
Entec Services, Inc. 

16-D Commerce Avenue 

Hueytown, Alabama 35023 

Telephone: (205) 491-6676 

Fax: (205) 491-6614 

Results of the December 13, 2006 

Emissions Testing on 

No. 1 and No. 2 Kilns Dry Lime Absorber Stack at the 

Cherokee Brick Facility in 

Macon, Georgia 

Submitted to: 

Cherokee Brick and Tile Co. 

3250 Waterville Road 

Macon, Georgia 31206 

Attention: Mr. Jim Owens 

Entec Project No. 26180 

Completed By: 

Report Submitted: January 5, 2007 

Reviewed By: 

Project Manager 

Tom Lotz 

Technical Services Manager 

hereby certify to the best of my knowledge all field sampling and laboratory analysis performed for 

this report is authentic and accurate. It has been checked for completeness and accuracy. 
Cherokee Brick and Tile Co. 

Table of Contents 

Section Page No. 

Executive Summary 

Emissions Summary 

Detailed Test Results 

Sampling Procedures 

Location of Test Ports 

Method 26A/5 Sampling Train 

No.1 No. 2 Kilns Dry Lime Absorber Field Data Sheets 

Test Run 1 

Test Run 2 

Test Run 3 

Control Room Data 

Quality Control I Quality Assurance Procedures 

QA/QC Checklist 

Orifice Check and Temperature Check 

Fyrite I Orsat Standardization 

Laboratory Analysis 

Equipment Calibrations 

Nomenclature and Test Calculations 

1 

2 

3 

7 

11 

12 

13 

14 

18 

22 

26 

28 

33 

34 

35 

39 

56 

67 
Executive Summary 

Cherokee Brick located in Macon, Georgia, retained Entec Services, Inc. to perform 

emissions testing on the No. 1 and No. 2 Kilns Dry l,ime Absorber Stack. Mr. Tommy I_otz, 

Jr., Mr. Jason English, and Mr. Ryan Harris, of Entec Services, Inc. conducted the testing 

on December 13, 2006. Representing Cherokee Brick was Mr. Jim Owens who coordinated 

testing with the control room production activity. 

Entec Services, Inc. encountered no difficulties in the field collection of the samples or in 

the laboratory analysis of the samples 

The emissions test summary on the following page gives a detailed summary of each test 

run compared to the maximum emission limits set forth by the Georgia Department of 

Natural Resources. Test results indicate the emissions results were below the 

emissions standards set forth by Permit No. 3251-021-0167-V-02-0, except for the 

Hydrogen Fluoride emissions in Ibslton of Fired Brick. 

Detailed Test 
Entec Se rvices ;-Inc: 

SOURCE OVERVIEW 

SOURCE OWNER: 

PLANT LOCATION: 

SOURCE(S) NAME(S): 

SOURCE(S) CONDITION: 

SOURCE(S) SHAPE: 

PROBE WASH CHEMICAL: 

SOURCE PERMIT NUMBER: 

TEST PERFORMED: 

ADDITIONAL TEST REQUIREMENTS: 

REFERENCE METHOD TESTS: 

PROJECT MANAGER 

ENVIRONMENTAL ANALYST PROJECT LEADER 

ENVIRONMENTAL ANALYST ASSISTANT 

ENVIRONMENTAL SPECIALISToVE READERS 

OWNER'S REPRESENTATIVE: 

RULING AGENCY 

DATES TESTS CONDUCTED: 

ENTEC PROJECT NUMBER: 

Cherokee Brick and Tile 

Macon. GA 

Dry Lime Absorber Stack 

Compliance Testing (New Feed Rate) 

Circular 

Acetone 

3251-021-0167-V-02-0 

Lime MACT Subpart JJJJJ 

Minimum Particulate Requirements 30 dscf 

Sample Location 

Volumetric Flow 

Molecular Weight 

Moisture Content 

Particulate 

Visible Emissions 

Hydrogen Chloride 

Hydrogen Fluoride 

Mr. Tommy Lotz Jr. 

Mr. Jason English 

Mr. Ryan Harris 

Mr. Tommy Lotz Jr. 

Mr. Jim Owens 

EPA Method 

EPA Method 

EPA Method 

EPA Method 

EPA Method 

EPA Method 

EPA Method 

EPA Method 

Georgia Department of Natural Resources 

12/13/06 

26180 

1 

2 

3 

4 

5 

9 

26A 

26A 
ENTEC Services, Inc. 

16-D Commerce Ave. Hueytown, Alabama 35023 

INPUT TEST DATA 

Client: 

Source: 

Cherokee Brick and Tile 

Dry Lime Absorber Stack 

Field Data 

Run Number 

Test Date 

Time Test Run Began Ended 

Sampling Time 

Stack Area 

Barometric Pressure 

Stack Static Pressure 

Pitot Tube Correction factor 

Job No.: 

Data Input By: 

26180 

Jason English 

Symbol Units Test Data 

1 2 3 AVERAGE 

12113/06 

0800-0912 

12/13/06 

Military Time 1000-1106 

12/13/06 

1250-1355 

8 minu•s 60 60 60 60 

A, F• 22.166 22.166 22.166 

P•r in. Hg 30.04 30.04 30.02 30.03 

C• 

Y 

0.17 

0.84 

0.15 

0.84 

in. H20 0.14 

0.84 

0.15 

0.84 

mg 

mg 

mg Total particulate collected 

Avg. Sq. Rt. of Delta P 

Stack Temperature 

Total Hydrogen Chloride collected, mg 

iTotal Hydrogen Fluoride collected, mg 

HCL 

HF 

(sqrt/•P)av• 

17.0 

3.0 

0.598 

336.7 

29.6 

83.5 

28.7 

CO2 

Impingers Weight Gain (Moisture) Wimp 

Silica Gel Impinger Weight Gain (Moisture) 

Oxygen Concentration, dry basis 

Carbon Dioxide Concentration, dry basis 

14.0 

6.0 

0.614 

338.3 

30.2 

86.4 

9.0 

Avg. Orifice Delta H 

F 

(in. H20) 

16.0 

5.0 

0.600 

339.5 

33.6 

78.6 

8.1 

15.7 

4.7 

0.604 

338.1 

31.1 

82.8 

15.3 

in, H20 2.01 2.12 2.02 2.05 

grams 114.3 119.8 119.5 117.9 

grams 17.5 18.2 13.7 16.5 

Meter Correction Factor 0.986 0.986 0.986 0.986 

Meter Delta H @ .•H@ in. H20 1.769 1.769 1.769 1.769 

Nozzle Diameter D, inches 0.312 0.312 0.312 0.312 

Meter Volume Yr, dcf 45.388 46.120 :43.876 45.128 

Meter Temperature t,, °F 72.2 77.5 83.2 77.6 
ENTEC Services, Inc. 

16-D Commerce Ave. Hueytown, Alabama 35023 

CALCULATED TEST DATA 

Client: Cherokee Brick and Tile 

Source: Dry Lime Absorber Stack 

Description Formulas 

Run Number 

Test Date 

Time Began-Ended 

1. Stack Pressure P• P•113.G 

2. Meter Pressure Pb,• t•H 113.6 

3. Standard Meter Volume 17.64" Y= (V•,//'.)* (P•,.• •H 113.61 

4a. Standard Volume of Water Vapor Condensed =0.04706•v• 

4b. Standard Volume of Water Collected in Silica Gel =0,0471s'w=• 

5. Moisture Fraction 

19. Molecular Weight Of Stack Gas, dry basis 

10. Molecular Weight Of Stack Gas, wet basis 

0.32"(O=)+ 0.44"(CO2)+0.28"(100-(O2)-(CO=)) 

M,'(1-B•)+lS.0*(B..) 

11. Average Stack Gas Velocity 

12. Stack Gas Flow @ Stack Conditions 

85.49"Cp*(sqrt &P)av,*SQRT((Ts) (Ps'M.)) 

6•'v$*A• 

13. Stack Gas Flow @ Standard Conditions 

14. Stack Gas Flow @ Dry Standard Conditions Qa*(I*B•)*(Ts•#Ts)'(PslP=•a) 

14b. Hydro•len Chlodde concentration @ Std.Cond.,Grains/Cu.Ft. =(0.01543*HCL•)IQ,• 

=(0,01543*HF•)IQ• 

=o.01543*m,/V•lst• 

14b. Hydrogen Fluodde concentration @ Std,Cond.,Grains/Cu.Ft. 

15. Particulate concentration @ Standard Conditions 

15b. Hydrogen Chlodde emissions, Ibs per hour =(60/'/000)*HCLQ=,•°Q,• 

15b. Hydrogen Fluodde emissions, Ibs per hour =(60/7000)*HFQ,.•*Q=• 

21. Particulate emissions (60/7000)'c,*Q,• 

22. Volume collected through nozzle =TJP,'[0.002669"V•=÷ V•*Y*P,4Tm] 

24. Isokinetic Sampling Rate, Percent 100"Vn/ 

Symbol 

B• 

M• 

M= 

v• 

Q= 

Q• 

HFcs 

HCI -Ibs/ht 

PMR 

V. 

Units 

Military Time 

in. Hg 

in. Hg 

d$cf 

scf 

scf 

fraction 

g/g-mole 

g/g-mok• 

scfm 

dscfm 

grldscf 

grldscf 

grldscf 

Ibs/hr 

Ibs/hr 

acf 

% 

Job No.: 26180 

Data Input By: Jason English 

Calculated Data 

2 3 AVERAGE 

12/13/06 12/13/06 12/13/06 

0800-0912 1000-1106 1250-1355 

30.05 30.05 30.03 30,04 

30.19 30.20 30.17 30.18 

44,782 45.065 42.387 44.078 

5.379 5.638 5,624 5,547 

0,825 0.858 0.646 0.776 

0.1217 0.1260 0.1289 0.1255 

29.160 29.520 29.440 29.373 

27.802 28.069 27.966 27.946 

41.95 42.87 42.05 42.289 

55,792 67,010 55,924 56,242 

37,124 37,861 37,054 37,346 

32,607 

0.010 

33,091 32,279 32,659 

0.010 0.O12 0.011 

0.029 0.030 0.029 0.029 

0.0099 0.0031 0.0029 0.0053 

2.85 2.93 3.38 3.06 

8.04 8.39 7.92 8.11 

2.76 0.87 0.82 1.48 

76.627 77.641 73.437 

95.57 94.76 9t .37 

75,901 

93.90 
Sampling. Proced u res 
Procedures 

The particulate and gas emission rates were determined using EPA Methods 1-5, 9, 

and 26A, CFR Title 40, Part 60, Appendix A. The calibration and quality assurance 

procedures of EPA CFR 40 Part 60 Appendix A for all methods, and the "Quality 

Assurance Handbook for Air Pollution Measurement System" Volume III Stationary 

Source-Specific Methods were followed throughout the duration of the field and 

laboratory testing. 

The most current revision revised as of July 1, 2004, of each method (as described in 

the Federal Register) was used. 

Stack Gas Volumetric Flow 

The velocity of the gas stream was determined according to EPA Reference Method 1 

and 2 by reading the instantaneous velocity head with an inclined manometer at each 

sampling point with a calibrated S-type pitot tube attached adjacent to the sample 

nozzle. The stack pressure was measured with the static side of an S-type pitot tube. 

A calibrated pyrometer was used to measure stack temperature at each sampling point. 

The stack was tested for cyclonic flow according to EPA Reference Method 1. 

Stack Gas Molecular Weight 

The carbon dioxide and oxygen concentrations were determined using EPA Reference 

Method 3 (Fyrite Method). A sample of the flue gas was extracted from the gas stream 

during each test. These samples were analyzed with a Fyrite gas analyzer. The 

molecular weight of the gas was calculated using the moisture, oxygen and carbon 

dioxide content and the measured stack gas temperature. 

Moisture Content 

The moisture content used for calculating the gas stream flow rate was determined by 

measuring the amount of condensed moisture in the glass impinger and silica gel 

impinger in the sampling train as described in EPA Reference Method 4 at the 

completion of each test. 
The moisture collection system consists of a series of 4 impingers connected to a silica 

gel impinger attached to the outlet. Ice is placed around the impingers to maintain a 

temperature <68 o F. The outlet temperature of the impinger is monitored and recorded 

throughout the duration of the testing to verify the temperature is below <680 F. 

Visual Emissions 

Three (3) one hour visual emissions tests were determined simultaneously with the 

particulate emissions by a certified Visual Emissions reader, Mr. Tommy Lotz, Jr. Mr. 

Lotz's certification documents can be found in Equipment Calibration section of this 

report. 

Hvdroqen Chloride / Fluoride with Particulate 

Preliminary data was used to determine stack temperature, pressure, and range of 

velocity heads, moisture content and stack gas dry molecular weight prior to sampling. 

The meter box was leak checked from the pump to the orifice. Initial and final leak 

checks of the sampling system and pitot lines were performed as outlined in Method 5 

and were recorded on the data sheets. The nozzle (glass with an angle of taper of 30 

degrees and of button hook design) was calibrated before and after the test using a 

micrometer and was also recorded on the field data sheets. 

The sampling probe was placed at each sampling point to provide a total sampling time 

of at least 60 minutes and a volume of at least 31.8 cubic feet. The gases were drawn 

through a glass nozzle attached to a heated glass lined probe. The probe was maintained at the proper setting to obtain a temperature of > 248 0 F. The gases then 

proceeded through borosilicate glass filter holder, with a Teflon frit filter support through 

a tarred Teflon or quartz fiber filter to remove particulate matter. The exit of the filter 

was maintained at a temperature of > 248 0 F. These temperatures were recorded at 

each point on the field data sheets. 

The gases were then scrubbed through a series of four impingers to capture hydrogen 

halides, and moisture. The optional moisture knockout impinger was not used in the 

sample train. The first and second impingers contained approximately 100 ml of a 0.1N 

H2SO4 solution and the third and fourth impingers contained approximately 100 ml of a 
H2SO4 solution and the third and fourth impingers contained approximately 100 ml of a 

0.1 N N•OH solution. The fifth impinger contained pre weighed silica gel to remove any 

remaining moisture. The gases passed through the impinger series in an ice bath to 

maintain a maximum exit temperature of 68 0 F. This temperature will be also recorded 

on the field data sheets. The clean and cool gases then entered the meter box where 

the gas flow and temperature were measured. 

After the completion of each test run leak rate determinations were made and recorded 

on the field data sheets. Then the sampling train and the probe nozzle assembly were 

transferred to the cleanup area making sure no particulate was lost. The cleanup data 

was also recorded on the field data sheets and / or the laboratory checklist sheet. 

Particulate catches were placed in sealed petri dishes. Each acetone rinse from the 

nozzle, probe, and filter holder were combined and placed in a sealed container. The 

first, and second impinger contents were transferred to its tarred container, weighed 

and the rinsing from the glassware will be added to this container. The third and fourth 

impinger contents were weighed for moisture determination calculations but were not 

kept for analysis. The silica gel from the fifth impinger was transferred to its respective 

tarred container and weighed. For the group of tests an acetone blank, sulfuric acid 

solution, distilled water and acetone of approximately 200 milliliters were placed in a 

sealed container. These containers will be clearly marked and transported to the 

laboratory for 

analysis. 

Enthaipy will perform all of the laboratory analysis and is an approved Louisiana 

accredited lab (Certification Number 04010) that meets all requirements for the State of 

Georgia approved and accredited laboratory. 
Entec Services, Inc 

16 D Commerce Ave. Hue•own, AL 35023 

STACK DRAWING & TRAVERSE POINT LOCATION 

Client: Cherokee Brick and Tile Job No. 26180 

Source: PCD01 Stack Input By: Jason English 

Type of Traverse: Velocity (V) or Particulate (P): P Port Type Flange Port Diameter 6.0" 

Stack Diameter, inches: 63.75 Stack Area, Ft•: 22.166 

Stack Height, feet: 100 Number of Ports: 2 

Stack Prol)erties: Inches Duct Diameters Length of Port. inches: 8.25 

Upstream Disturbance: 170.0 2.67 Total Number of Traverse Points: 12 

Downstream Disturbance: 684.0 10.73 Number of Points per diameter:. 6 

63.8 INCHES 

Inside Stack Outside Nipple 

Point No. Inches Inches 

170.0 INCHES 

684.(; NCHES 

2.8 11.1 

2 9.3 17.6 

3 18.9 27.1 

4 44.9 53.1 

5 54.4 62.7 

6 60.9 69.2 

Adjusted points diameter • 24" no point closer than 1.0 inch 

Adjusted points diameter < 24" no point closer than 0.5 inch 

Stack Diameters between 12-24 inches minimum points are 8 

4 points per port if the 8 2 diameters downstream and 

upstream criteria is met. 
Method 26A/5 Sampling Train 

(•)• 

Filter Exit Temperature 

(>248 F) 

mp•nger 

:: .- 

T•mp•Ia• lOOml lOOml 

Sensors 0.1N 0.1• 0.1• O.1N 

•so• 

Impinger Exit Temperature 

(<68 F) 

Ice Bath 

Exhaust 

12