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.comEntec 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 12371112131418222628333435395667Executive 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 TestEntec 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

12345926A26AENTEC 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 1000-1106 Military Time 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

mgmgmg Total particulate

collected Avg. Sq. Rt. of Delta P Stack Temperature Total Hydrogen

Chloride collected,

mg iTotal Hydrogen

Fluoride collected,

mg

HCLHF (sqrt/•P)av• 17.03.0 0.598 336.7 29.6 83.5 28.7 CO2Wimp Impingers Weight Gain (Moisture) Silica Gel Impinger Weight Gain (Moisture) Oxygen Concentration,

dry basis Carbon Dioxide Concentration,

dry basis 14.06.0 0.614 338.3 30.2 86.49.0 Avg. Orifice Delta H

F (in. H20) 16.05.0 0.600 339.5 33.6 78.68.1

15.74.7 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

77.6ENTEC 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

PMRV. Units

Military Time in. Hg in. Hg d$cf scfscf 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 93.90Sampling. Proced

u resProcedures 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 wasmaintained 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 aH2SO4 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