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•com 
ENTEC 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 

97,98 
ENTEC 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 

10.9 

t6,0 

3,5 

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 2.9 
ENTEC Services, Inc. 

CALCULATED TEST DATA 
3,7t7o0 

23,1870 

o.•i% 

22,6737 9.8240 

14,4 

3,45 

26.75 

3.45 

2.76 2i75 

•0,1 

9.7 

17,40 

3A5 

2•59 

22•1 
EN 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,com 
E 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. 

1 

2 

3 

7 

11 

12 

13 

14 

18 

22 

26 

28 

33 

34 

36 

37 

38 

39 

42 

55 
Exe ,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 

1 

2 

3 

4 

5 

9 
ENTEC 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..5 

3.0 

08/25105 

131•5-1417 

AVERAGE 

29.30 

-0.18, -0,16 

974 

42.056 

92.2• 

1 

82.2 

7,2 

18,0 

3.0 

0.84 

•-974 

1.913 

0.310 

42.801 

86.8 

80.9 

g.7 

16,2 

3,2 

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 2.9 
ENTEC 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 were 
they 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•