p•ol

P•llU•on Oo.•I $•st•m Evatu•:

and $our• EmtSs|ons

Te•ting Belden Brick

Company Sugarcreek, Ohio Annual Compliance

Testing Brick Plant Number

3
Aught •, 2005 Entec P•ect No,: 26126

• phone: (205) 49t-6676

Fax (205) 491-6614 16•D Commerce

Avenuo Huey•own,

Alabama 350 www;eltte cserv|¢es•comENTEC Services,

inc.

Belde• Brick Company Br•k Plant No. 3

CALCULATED

TEST DATA

Mete• Pressu•
4a• Sta• Volume of Water Vapor Conda•'sed Standard Volume o• W•e• II II

5. Mc•sh•re Frac•o• 3:7t3 0,514 0,094,2
10, Molecular Weight Of Stacl¢ Gas. wet b•sts

K•'(i-B,,J+tC¢*(•

•, • 2&145 •_2. $tac• Gas Fk• • S•ac• C•d•tio•s t3. Stac• Gas Fk•@ Sta•ard Cor•s AVERAGE

29,29 29,42 39.576 •;497

39.571 3.840 3.868

3,•07 0.5•9__• 8,339

0.457 &0992 0;0985

0 0'373 •..•:•.• 2•:•

•..•:• •,35 37,67 •;•
17;9t8 17,563

0,0037 0;0150

0,•088 0.t5 0,04

97,98ENTEC Services,

Inc.

Client: Source: Field Data INPUT TEST DATA Belden Brick Company Brick Plant No. 3 Symbol

c,Y Run Number Test Date Time Test Run Began Ended_. Sa_•!!on • Time Stack Area Barometric Pressure Stack Static Pressure Pitot Tube Correction factor Meter Correc•on Factor Meter Delta H_•L_ Nozzle Diameter Meter Volume Meter Tern erature A•v•I. Odfice Delta a tmpingers Weight G.a!n (Moisture)

w•, _Silica Gel mpinger Weight Gain (Moist.•.e) •Oxygen CQ•centration,

d• basis Carbon Dioxide Concentration,

dr)• b•_i•s

co• Avg. Sq. Rt of Delta P Stac k Temp•,ra!u m Total condensible

particulate collected Total particulate collected Job Data Input By: Units

mlnute= 1

in. Hg O8,'25/05 1019-1121

Pr 12.566

t2.566 2&30

•F

% 0.•4 1.913

82.7 1.65 78.9 10.9t6,03,5 0,529 365,0

25126 La|an Kirby

0.974 Te• Data 08/25/05 08125/05 1t47--1249 I315-t417 60 ,,6D

! 29.30 •g•0, I 29,30 I -0.14 -0.• L -0.16 &84 •84

0.• 0.974 0;974 1.9•3 1,913

1.913 0.3t0 0•310

0.3t0 42,720 42,056

42.801 85,7 92.2

86,8 1.66 1.60

.• 8t.6 82,2

80,9 1.0 7,2

9.7 1&5 16.0

I6,2 3,0 3.0

3.2 0.530 0.520

0,526 37&8 375.4

371.4 38,4 •.1

23.4 2.7 0.7

2.9ENTEC Services,

Inc.

CALCULATED TEST DATA3,7t7o0

23,1870 o.•i% 22,6737

9.8240 14,4

3,45 26.75 3.45

2.76 2i75 •0,19.7

17,40 3A5

2•59 22•1EN TEC

Servic es Pollution Control System Evaluation

and Source Emissions

Testing September 19, 2005 Mr, John Jensen Belden Bdck Company 475 Dover Road Sugarcreek, OH 44681 Re: Compliance

Testing

for Particulate

and Visible

Emissions Brick Plant No, 3 Tunnel Kiln Sugarcreek, Ohio Entec Project No.: 25126
Dear Mr• Jensen, Please find the attached

three copies of the compliance

emissions

testing for the Br{ck Plant No. 3 Tunnel Kiln performed

at your facility on August 25, 2005. We appreciate

Me oppottuni•

to perform

this project

for you and hope to be of assistance to you in the future. If you have any questions

please call 205t 49%6676. Sincerely, Entec Se ices,

Inc,
Erik Groth Project Leader

Commerce

Avenue

Hueytowr•,

Alabama 35•23 Phone: (205} 491=6676

Fax (205) 491 www.entecservtces,comE ntec

S ervi

ces,

In c. 1,6 D Commerce

Avenue Hueytown, Alabama

35023 Telephone: (205) 491-6676 Fax: (205) 491-6614 Results of the August

25, 2005 Compliance Testing

for Particulate

and Visible

Emissions

on the Brick Plant No. 3 Tunnel

Kiln located

in Sugarcreek, Ohio Facili• Permit

No. 06-79-00-0118,

ID No. P301 Submitted to: Belden Brick

Company 475 Dover Road Sugarcreek, Ohio 44681
A•ntion: Mr, John Jensen Entec Project No. 25126 Completed By:

Erik 8ro• Project Leader Report Submitted:

Se•mber

t9, 2005 Reviewed By:

Tom Lotz QNQC Manager
hereby certify to the best of my knowledge

alt field sampling

and laboratory

analysis performed for this report is authentic

and accurate.

It has been choked for completeness

and accuracy.Belden Brick

Company Tabi!e,,, of Conten• SecU,o,n,Executive Summary Emissions

Summary Detailed Test Results Sampling Procedures Location of Test Ports Diagram of :Sampling

Train Particulate and Visible

Field Data Sheets Test Run 1 Test Run 2 Test Run 3 Control Room Production

Data Quality Assurance

I Quali•

Control

Procedures QA 1 QC Checklist Stack On-site

Measurements Odflce Check and Temperature

Check Preliminary Traverse

w/Cyclonic

Flow Fydte / Orsat Standardization Laboratory Anal•is Equipment Calibrations Nomenclature and Test Calculations Parle No. 123711121314182226283334363738394255Exe ,utive Summaw Entec Services,

Inc. was retained

by Belden Bdck Company

to perform

particulate

and visible emissions

testing on Brick Plant No. 3 Tunnel Kiln located in Sugarcreek,

Ohio. Mr. Joseph

Lotz, Mr. Eddie Rudloff

and Mr. Lalan Kirby of Entec Services,

Inc conducted the testing on August 25, 2005. Mr. John Jensen

was present

from Belden Brick and to coordinate

testing with control room activities. Particulate and visible emissions

were performed

on the Brick Plant No,3 Tunnel Kiln which has a dry scrubber

and a baghouse

to control emissions.
No d•culties

were encountered

in the field collection

of the samples

or in the laboratory analysis

of the samples

by Entec Services,

Inc.
The particulate

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 State of Ohio Environmental

Protection

Agency.

Tests results

indicate

the average particulate and visible

emissions

are below the limita set forth by the State of Ohio EPA for Facility

Permit No, 06-79-00-0118,

Facility

Source

Identification

No, P301.SOURCE OWNER: PLANT LOC, J•TION: SOURCE(S) N•S): SOURCE(S) CONDI•ON: SOURCE(S) SHAPE: PROBE WASH CHEMICAL: SOURCE PERMIT NUMBER: TEST PEI•ORMED: REFERENCE METHOD TESTS:

PROJECTMANAGER ENVlRONMENT•J-ANALYST PROJECT LEADER ENVIRON•NTAL ANALYST-

A•$tSTAN• ENVIRONMENTAL SPECIALIST

VE READERS OWNER*S •RESENTATIVE: RULING AGENCY RULING •ENCY REPRESENTATWE: DATES 11•TS CON[•CT•D: ENTEC PROJECT Nt,MBER:

Entec

Sewices,

Inc. SOURC, E,,•VERVIEW

123459ENTEC Services,

Inc.
•o co• Av•. •,•r•. • •o• INPUT TE•T DATA Client: Belden Brick Company Job No.:

25126 Source: Brick Plant No. 3 Data Input By:

Lalan Kirby. Field Dat• Run Number Test Date Time Test Run Began Ended Sampling Time Stack Area Barometric Pressure, iStackSta!cPressure iPitot Tube Correction

factor Meter CoKection

Factor Meter Delta H .@,..__ Nozzle Diameter Meter Volume Meter T em_peratute Av•go 0r•ce Dela H Irnin ers Wei ht Gain •'•0isture) Silica Get Impi;nger Wei ht Gain (Moisture) Oxygen Concentration,

dry basis Carbon Dioxide Concentration,

dry b•s!s Avg. Sq. Rt: .o.f Delta P Stack Temperature Total condensible

particulate

co,!!ected Torsi t•articulate

colle• 08/25/05

•est Data 2 08/25/05 1147-1249 3

60 6O 12.566 12.566

12,• 30 29,30

29°30 0,84 0.974
0:3t0 43•628 82.7 1.65 78,9 t0.9 0:84
1;913 0,310 42.720 85,7
81.6
t6..53.0

08/25105 131•5-1417

AVERAGE

29.30 -0.18, -0,16
974

42.056 92.2• 182.27,218,03.0 0.84•-974 1.913 0.310 42.801 86.8
80.9g.716,23,2 0.529 0•530 365.0 373,8 9.7 38,4 5.2 2,7

0,520

0.52•___ 375,4 371.4 22,t 23.4 0.7 2.9ENTEC Services,

Inc.
CAL•TED •ST DATA
C•ie•: •t•n B•k Com•ny J• No•

25t2•

2 3 A•P•GE

2. Met• Pr• =•

p. • 2•.•:42

•.42

29•42

29.42

0;51 9

0.457

1+ 2 0.9•Procedures The particulate

emission

rates were determined

using EPA Methods

1-5, CFR Title 40, Part 60, Appendix

A. The calibration

and quality assurance

proc•ures

of EPA CFR 40 Part 60 Appendix

A for all methods,

and the "Quality

Assurance

Handbook

for Air Pollution Measurement

System"

Volume

Iil Stationary

Source-Specific

Methods

were followed throughout

the duration

of the field and laboratory

testing. The most current revision

revised as of July I, 20•, 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 insta•aneous

velocity

head with an inclined

manometer

at each sampling point with a ca{ibrated

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 (Fydte 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 stainless

steel condenser

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 four glass impingers.

The first two impingers
were charged

with 100 ml each, the third empty, with the fourth charged

with silica gel. Ice is placed

around

the impingers

to maintain

a temperature

<68 o F. The outlet temperature of the condenser

is monitored

and recorded

throughout

the duration

of the testing to verify the temperature

is below <68 o F. Particulate Determination The particulate

sample

train consists

of a heated stainless

steel sample probe and liner equipped with a S-type Pitot tube and thermocouple,

The probe is attached

to a sample module consisting

of a heated filter compartment

which houses

the in-line filter holder equipped with a pre-weighed

glass fiber filter for the colle•ion

of the particulate

and impingers for determining

condensed

moisture.

The sample

module

is connected

to a control module

by means of an umbilical

cord. The control module

consist of a dry gas meter, calibrated

orifice,

leak free pump, two inclined

manometers,

temperature controllers for the heated filter compartment

and probe and a thermocouple

indicator

to monitor the required

temperatures

during the testing. Particulate samples

are collected

as follows:

The sample

gas is drawn through

the sampling probe isokinetically

and passed

through

a 3-inch Whatman

glass fiber filter where particulates

are removed.

The Sample gas is then passed

through

the umbilical cord to an ice-cooled

condenser

and desiccant-packed

column,

which absorbs

any remaining moisture.

The sample gas then passes through

a vacuum

pump followed

by

a dry gas meter. The dry gas meter integrates

the sample

gas flow throughout

the duration of the test. A calibrated

orifice attached

to the outlet of the dry gas meter provides real time flow rate data.
A representative

particulate

sample

is acquired

by sampling

for equal pedods

of time at the centroid

of a number

of equal area regions

in the exhaust

stack. The sampling

rate is adjusted

at each test point maintaining

an isokinetic

sampling

condition. After the sampling

is complete,

the filter is removed

and placed in a storage

container for shipment

back to the laboratory

for analysis.

The nozzle, probe liner and inlet side of the filter holder are quantively

washed

with a reagent

grade acetone

and: stored in a marked and sealed container.

The samples

are transferred

back to the laboratory

werethey are logged in and analyzed.

The volume

of acetone,

rinse is noted and transferred to a tarred fleaker and evaporated

off at 97-105 OF. This temperature

is.used to prevent condensation of atmospheric

moisture

due to the •oling

effects

induced

by the evaporating acetone.

The acetone-free

sample is placed in an oven and dded at 105 °C for thirty minutes

and then placed in a desiccator.

After the sample has desiccated

for twenty-four hours the sample

is weighed

to the nearest

0.1 mg. The filter sample

is transferred to the original

petri dish in which the original

weight was obtained

and placed in a d•/ing oven for 2 hours at 105 °C. The filter and petri dish are then placed in
a desiccator.

After the filter and petri dish have desiccated

for twenty-four

hours the sample is weighed

to the nearest

0.1 mg. Visual examination

of the samples

are made to determine

if any unusual

characteristics

of the samples

are observed•

The weight of the acetone

rinse is corrected

for the weight of the acetone

blank.Entec Services,

lnc
STACK DRAWING

& TRAVERSE

POINT LOCATION .,•,.,,!•-:•,•:::::.• Client: Belden Brick Company Job No. 2§126 Source: Bdck Plant No. 3 Input By: Lalankirby Type ofTraveme:

Vel(•:tty (V) or Particula• (P):

•

Port Ty•

Fla• Port Oismeter

4 Stack Dla•tar, Inch•s:

4• Stack Area, F•: I• S•Ck •ght, •

• Num•r • P•: 2 S•¢k Pto•s:

Inches

Bu• D•mm

Le• • Po• inch.: 7•

B•r• D•

4•.0

•75

Num•r • Pol• •r diam•

8 48,0

120.( NCHe.S

420.( Inside Stack

Outside Nipple Point No,

lnch, es

Inches 2 7.0

14.5 3 14,2 21# 4 •,8 4%3

AdjUsted points dtametar > 24" no pot• ¢• than t.0 Inch "Adjus•d points diameter <_ 24' n¢) point closer th• 0,S inch Stack Diameters between t2-24 irmhes minimum po;c•s Me8 4 points per port if the 8 :l diameters downstream

and upstream critaris iS m•