ENTEC Serw es
Pollution Control System Evaluation

and Source. Emission•

Te•stiiig
Pine HaftBrick
c•;...•.,., Georgia
Initial Compliance Kiln No. 2 DLA Outlet

July 20, 2005 Entec Project No, 25144

16 D Commerce

Avenue

Hueytown

Alabama

205-491-6676"

Toll Free 1-800-429-8445

www.Entecservices.comEntec Services,

Inc. 16 D Commerce

Avenue Hueytown, Alabama

35023

Results of the June 22, 2005 Initial Compliance

Testing

for Emissions

on the No. 2 Kiln DLA Outlet
•...&•.J •1. Facility in Fairmount,

Georgia GEPD Permit

No. 3251-129-0073-S-01-1 Submitted to: .Pine Hall Brick

Company,

Inc. P.O. Box 836 Madison, North Carolina

27025 Attention: Mr. Harold

Newman

Entec Project

No. 25144

Project Manager Report Submitted:

July 14, 2005 Reviewed By:

John T. Sutton President
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,

accuracy,

and conducted in accordance

with the applicable

EPA test procedures

as amended

by the applicable subparts.Pine Hall Brick

Company,

Inc. Table of Contents

Section Executive Summary

wl Emissions

Summary Detailed Test Results Cont.rol Roo.m._ p_r_nductinn

Data Sampling Procedures Particulate Field Data Sheets Instrumen.tal Field Data Sheets Location •'•-Test

Ports P"relin•in•ry Traverse

& Cyclonic

Flow Test Results "Quality Control

I Quality

Assurance

Procedures Pa•ae No. 13791831444649 Analyzer Interference

Checks Particulate and Flow Equipment

Calibrations Instrumental Analyzer

Calibrations Calibration Gas Certifications Laboratory Analysis Test Calculations

and Nomenclature 5867838898118Executive Summar• Entec Services,

Inc. was contracted

by Pine Hall Brick Company,

Inc. to perform emissions testing

on the No. 2 Kiln DLA Outlet at the Fairmount,

Georgia

facility.

Mr. Tommy Lotz, Jr., Mr. Lynn Beane,

Mr. Tim Draheim,

Mr. Joseph

Lotz and Mr. Eddie Rudloff of Entec Services,

Inc. conducted

the testing on June 22, 2005. Representing Pine Hall Brick Company

was Mr. Harold

Newman

who coordinated

testing

with the control room production

activity. Particulate, Hydrogen

Chloride,

and Hydrogen

Fluoride

emissions

testing

was performed in accordance

with EPA CFR 40 Part 60 Appendix

"A" methods

1-5 and 26A. Instrumental analysis

of stack gases was performed

in accordance

with EPA CFR 40 Part 60 Appendix

"A" methods

3A, 6C, and 10. Three

sixty (60) minute test runs were performed on this source with the operations

at approximately

nin.ety (90) percent

load. A method

6C interf_.er_.ence

check was performed

in conjunction

with Method

6C because _the/,ana!yz•er

used had not previously

been checked

when testing a Brick Kiln as'req•red for QA./QC

procedures.

; 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 Environmental Protection

Department

(GEPD).

Tests

results

indicate

that the emissions results

are below the emission

standards

set forth by GEPD Permit

No. 3251-129-0073-S-01-1.Test

Performed

For:

Source Tested: Test Condition: Test(s) Performed:
Run Number Emissions

Summary
Pine Hall Brick Fairmount, Georgia
Kiln No. 2 DLA Outlet Initial Compliance Particulate, HCI, HF, and Gas Testing

Testing Performed

By: Birmingham Division Project Manager'. Mr. Tommy Lotz, Jr.

Run I Run 2 Run 3 Average Date of Run Start Time Stop time 6/22/05

6122/05

6122/05 0945-1058 1205-1314

1355-1500 16.2 16.2

16.2

16.2 16.2 16.5

16.9

16.5 2.4 2.2

2.0

2.2 5.3 6.9

7.1

6.4 66.7 60.0

53.2

60.0 107.03 104.09

104.31

105.14 367 369

370

369 9.68 9.94

9.24

9.62 40.84 40.09

43.16

41.36 29,525 28,980

31,197

29,901

Permit 16,699 16,301

17,649

16,883

Umits Control Room Data, Tons of Brick Produced Oxygen Concentration,

% Carbon Dioxide Concentration,

% Sulfur Dioxide Concentration,

ppm Carbon Monoxide Concentration,

ppmIsokinetic Sampling Rate, % Stack Temperature,

°F Moisture Cpnte trt•%-volu•e Stack Gas Velocity, F/S Stack Gas Flow, P•CFM" Volumetric Flow Rate, DSCFM Visual Emissions,

highest SMA Particulate Emissions Particulate Emissions Particulate Emissions Sulfur Dioxide Emissions Sulfur Dioxide Emissions Sulfur Dioxide Emissions. Carbon Monoxide

Emiss=ons Carbon Monoxide

EmissiOns Hydrogen Chloride Emiss, ons Hydrogen Chloride Emiss=ons Hydrogen FI,ouddp Emissions Hydrogen Flouride Emiss=ons

%

0.0

0.0

0.0 grldscf 0.004

0.014

0.008 Lbs/Hr 0.59

2.01

1.21 Lbs/Ton of Brick

0.04

0.12

0.07 Lbs/Hr 0.88

1.12

1.25 Tons/Year 3.87

4.92

5.48 Lbs/Ton of Brick

0.05

0.07

0.08 Lbs/Hr 4.86

4.27

4.10 Lbs/Ton of Brick

.0.30

0.26

0.25 grldecf 0.002.

0.002.

0.002 Lbs/Hr 0.i06

0.311

0.325 grldscf.'. 0.001

0.001.

'.0J)01 Lbs/Hr 0.180

0.183

0.182

0.0 0.009 1.27

2.80 0.081.09 4.75 0.07 4.410.27 0.002 0.314 0.001 0.182 0.975 The visible emissions

from this source were

below The Lbs/Hr particulate

emissions

from this source were

below The Tons/Year

sulfur dioxide emissions

from this source were

below The Lbs/Hr hydrogen

chloride emissions

from this source were

below The Lbs/Hr hydrogen

flouride emissions

from this source were

below

the applicable

standards. the applicable

standards. the applicable

standards. the applicable

standards. the applicable

standards.Detailed Test

ResultsSOURCE

OWNER:
PLANT LOCATION: SOURCE(S) NAME(S): SOURCE(S) CONDITION: SOURCE(S) SHAPE: PROBE WASH CHEMICAL: SOURCE PERMIT NUMBER: TEST PERFORMED: REFERENCE METHOD

TESTS:•

PROJECT MANAGER ENVIRONMENTAL ANALYST

PROJECT

LEADER ENVIRONMENTAL •AI•ALYST-

ASSISTANT ENVIRONMENTAlly_SPECIALIST VE READERS
OWNER'S REPRESENTATIVE: RULING AGENCY RULING AGENCY

REPRESENTATIVE: DATES TESTS CONDUCTED: ENTEC PROJECT

NUMBER:

Entec

Services, inc. SOURCE OVERVIEW

Pine Hall Brick Fairmou•, Georgia Kiln No. 2 DLA Outlet Initial Compliance Circular
Acetone 3251-129-0073-S-01-1 Particulate, HCI, HF, and Gas Testing Sample Location

EPA Method

1 Votumeldc Flow

EPA Method

2 Molecular Weight

EPA Method

3A Moisture Content

EPA Method

4 Sulfur Dioxide

EPA Method

6C Visible Emissions

EPA Method

9 Carbon Monoxide

EPA Method

10 Particulate EPA Method

26A Hydrogen Flouride

EPA Method

26A Hydrogen Chloride

EPA Method

26A
Mr. Tommy Lotz, Jr.
Mr. Tommy Lotz, Jr.
Mr. Joseph Lotz Eddie Rudloff Mr.Harold Newman Georgia Environmental

Protection

Department
None 06f22/05 25144ENTEC Services,

Inc.
16-D Commerce Ave.

Alabama 35023 INPUT DATA Client: Source:

Run Number Test Date

Pine Hall Brick Kiln No. 2 DLA Outlet Field Data

Symbol

Time Test Run Began Ended Sampling Time Stack Area Barometric Pressure Stack Static Pressure Pitot Tube Correction

factor Meter Correction

Factor Meter Delta H @ Nozzle Diameter Meter Volume,. Meter Temperature Avg. Orifice Delta H Impingers Weight Gain (Moisture) Silica Gel lmpinger Weight Gain ('Moisture) :)xygen Concentration,

dr), basis ;arbon Dioxide Concentration,

dry basis ;ulfur Dioxide Concentration,

dry basis :arbon Monoxide

Concentratio.•n,

dry basis otal Hydrogen

Chlodde Collected otal Hydrogen

Flouride Coil•cted vg. Sq. Rt. of Delta P lack Temperature •tal particulate

collectbd Job No,:

25144

PbarP9C=
Y

Dn

W•

COzSO2

coHCl
HF Units

Bilitary Time

Ft =

inches dcfF in. HzO grams grams %%ppm ppmmgmg (in. HL, O) lrz °F

Data Input By:

Tommy Lotz, Jr. Data
06122/05 0945-1058

29.36 -0,23 0.84 0.985 1.95! 0.310 48.500 73.01.99 98,77,516,22.45.366,7 6.469 3.809 0.567 366.612.5 06/22/O5 1205-1314

12.048 29.36 -0.24

0.985 1.95I 0.310 46,407 77.11.9095.38.616,52,26,960.0 6.394 3.750 '.0•555 368.7 41,2

06122/05 1355-1500

12.048 29.36 -0.24 0.84 0.985 1.951 0.310 50.365 77.72.2199,5

2,07,153.2

AVERAGE

OU

29.36 -0.24 0.84 0.985 1.951 0.310 48.424 75.92.03

16.52.26.460.0 6.700 6.521 3.755 3.771 0.598 0.573 370.3 25.0 368.5 26.2

5ENTEC Services,

Inc. i.:ii•i-'-::!:•:•:•i•i:i:!::::::::: 16-D Commerce Ave. Hue own, Alabama 35023 ::":: .......,-:-.-.:-',-:.-:!!•i•i!ii•!ii CALCUEATED DATA Clienf• Pine Hall Brfck Job No,:

25144 Source: Kiln No. 2 DLA Outlet Data Input By: TO,..,• Lotz, Jr. Description S ,•bo; Units

Ca-'-- •::--3=d Data •un Number Test Date Time Began-Ended 1. Stack Pressure P• P•113,6 2. Meter Pressure P•,. aZl 13.6 3. Standard Meter Volume 17.•4" Y* (V,,,/T.,)* (p•, •-I 113.6) ta. Standard Volume of Water Vapor Condensed =0.0470•W•= 4b. StanG=• Volume of Water Collected in Silica Get ==:•,• "nm• 0945-105 8 in. Hg 29.34 in.Hg 29.51

• 46.652

5. MoF•iure Fraction 9. Molecular Weight Of Stack Gas, dry basis 10. Motecular Weight Of Stack Gas, wet basis 0.32"(O•- O.44*(CO=)H).28*(100-(Oz)-(CGz))

1. Average Stack Gas Velocity 12. Stack Gas Flow @ Stack Conditions 1.4. Stack Gas FIo• @ D•_•Standard/Conditions 15• Particulata concenb-ation

@ Standard Conditions 15. Hydrogen Chloride concentration

@ Standard Conditions 15. Hydrogen FIo udde co ncentration @ Standard C ondition s 16. Sulfur Dioxide (SO2) Gas Cortcentmtion !6. Carbon Monoxide (CO) Gas Concentration 21. Particulate emission s !t. Hydrogen Chlodde emissions 21. Hydrogen Floudde emissions 21. Suffur Dioxide (SO2) Gas Concentration 21. Carbon Monoxide (CO) Gas Concentz-ation 2

3 AVERAGE

29.34 29.34

29.34 29.50 29.52

29.51 44.289 48.051

46.331

29.032 29.012 4.645 4.485

4.682

4.604 0.354 0.405

0.212

0.324 0.0994 0.0924

0.0962 28.996 29.013 g/g-mole 27.964

27.917

27.979

27.954 '•-•*C•*(sqrt •P),•*SQRT((T=)

(p,*M,,)) v. fUs 40.84

40.09

43.16

41.362 SO*v=*A O• a•m 29,525

28,980

31,197

29,901 Q'*(I"B")*(T==a/I', )*(PJP,=a| O,• ,•,;,, 16,699

16,301

17,649

16,883 =0.01543"mJV.•,• ¢= •,-,'•,,• 0.0041

0.0144

0.0080

0.0088 ==O.01543*HCIm,/V•==• HCle, •,;,L•,; 0.0021

0.0022

0.0022

0.0022 =O.01.•I3*HFmJV,•,• HFe= g#dscf 0.0013

0.0013

0.0012

0.0013 =C•,= MW 138•.1 10 c,==

8.82E-07

1.15E-06

1.18E-06

1.07E-06 =C•, MW 138•.1 10 C• Ibs/dscf 4•85E-06

4.36E-06

3.87E-06

4.36E-06 (60•000}*c=*Q• PMR Ib/hr 0.59

2.01

1.21

1.27 (60/7000)*HCIc.*Q,• HCl PMR Ib/hr 0.31

0.31

0.33

0.31 (60/7000)*HFc,*Q• HFPMR Ib/hr 0.18

0.18

0.18

0.18 =Cso• Q== S0 sO, ._--•-•r Ib/hr 0.88

1.12

1.25

1.09 =Coo Qsta 6• CO•b/hr Ib/hr 4.86

4.27

4.10

4.41 22. Volume.=llectad

through nozzle

=TJP,'[o.na•'•z*--

V==+ v,.'Y*P.,rr, j v, aof 82.483

78.738

84.938

82.053 •4. Isok;.• Sampting Rate, Percent 100*Vnl (60*v */•*e) •:•:•:•$•:•:•:•$•:•:•$•:•:•:•:•::•:::•:•::::•::•::•:::•:•:::::•::`:-:•.:.:`:•:•:•:•:•;•`•`:•::•'.`•'`•.-`-•.•.•-`.•.'•-`'•..`•``•':'`.`•`•`•:•"

107.03

104 09 104 31 105 14
'est Meter Orifice Cal. (E,C ALT.009 yqa, "l Y=

0.9483

0.9733

0.9659

0.9625Control Room

Production Data8Sampling ProceduresProcedures The

particulate

emission

rates were determined

using EPA Methods

1-5, 3A, 6C, 10, 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

I!i 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 Eead/ing

,the• instantaneous

velocity

head with an inclined

manometer

at each sam•01in• point with a calibrated

S-type

pitot tube attached

adjacent

to the sample nozzl.e: •, copy of the sample

point / port for each source

is located

in the section "Location of Sample

Ports".

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 EPP, Reference Method

1. Stack Gas Molecular

Weight-Instrumental The carbon

dioxide

concentrations

were determined

using EPA Reference

Method

3A. The molecular

we•ight 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 weighing the amount

of condensed

moisture

collected

in the impingers

of the sampling train as described

in EPA Reference

Method

4.Particulate, Hydrogen

Chloride,

and Hydrogen

Fluoride 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 data sheets.
The sampling

probe was placed at each sampling

point to provide

a total sampling

time of 60 minutes.

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 an exit temperature of above. 2480 F. The gases then proceeded

through

borosilicate

glass filter holder,

with a •'l;eflon

frit filter support

through

a glass fiber filter to remove particulate m•tter,

The filter was maintained

at a temperature

of above 2480 F. These temperatures were .recorded

at each point on the data sheets. ; The gases were then scrubbed

through

a series of four impingers

to capture

hydrogen halides and halogens

and moisture.

(The optional

first impinger

for a knockout

for moisture was not used.)

The first and second

impingers

contained

approximately

100 ml of a 0.1N H2SO4 solution

and the third and fourth impinger

contained

approximately 100 ml of a 0.1 N NaOH solution.

The fifth impinger

contained

pre weighed

silica gel to
remove any remaining

moisture.

The gases pass through

the impinger

series in an ice bath to maintain

a maximum

exit temperature

of 68 0 F. This temperature

was also recorded on the• data sheets.

The clean and cool gases then entered

the meter box where the gas flow and temperature

were measured. After,the.•,ompletion of the test'the

sampling

train and. the probe nozzle assembly

was transferred to the cleanup

area making

sure no particulate

was lost. The cleanup

data
was recor•ied.Particulate catches

were placed

in sealed petri dishes.

Each acetone

rinse from the nozzle, probe, and filter holder was combined

and placed in a sealed container.

For the group of tests an acetone

blank of approximately

200 milliliters

was placed in a sealed container. The first and second

impinger

contents

were transferred

to its tared container, weighed

and the rinsing

from the glassware

were added to this container. The third and fourth impinger

was transferred

to its respective

tared container,

weighed and the rinsing from the glassware

was added to this container.

The silica gel from the fifth impinger

was transferred

to its respective

tared container

and weighed.

A blank of containers were clearly marked,

logged in, and shipped

to a State of Georgia

approved certified laboratory

for analysis. Oxv_•en The oxygen

content

in the flue gas was determined

using a Siemens

Ultramat

23 oxyg•e.n •.,n•llyz_/er.

The Ultramat

23 uses an electrochemical

cell that consumes

oxygen from the .atmos•)her•

surrounding

the cell. The consumption

of the oxygen

generates

a proportional electrical

current.

This current

is then amplified

and provides

a signal output of 4-20ma

signals,

which corresponds

to a full-scale

range of 0-25% oxygen.
Carbon Dioxide Carbon dioxide

concentrations

were continuously

measured

with a Siemens

Ultramat 23 non-dispersive

infrared

(NDIR) analyzer.

The theory of operation

for this analyzer

is based on the principle

that CO2 has a unique

absorption

line spectrum

in the infrared region. The instrument

consists

of an infrared

light source,

a chopper,

a measurement cell, and a detector.

The infrared

tight beam emitted

by the source passes

through

the measuring cell,_which

is filled with a continuously

flowing

gas sample.

The light beam is partially absorbed

or attenuated

by the gas species

of interest

in this cell before reachihg the front.chamber

of tl•e detector.

Both the front •l•t•i rear chambers

of the sealed detector

are filled with a reference

gas. The difference

in the amount

of light absorbed between

the front and rear chambers

are dependent

on the concentration

of the gas species

of interest

within the sample

measurement

cell; a pressure

differential is thus created

between

the two chambers.

This pressure

difference

is then observed

12as

gas flow by the micro-flow

sensor

located

in a channel

connecting

the two chambers. The resulting

AC signal from the micro-flow

sensor

is rectified,

amplified

and linearized into a 4-20ma

signal for output that corresponds

to a full-scale

0-25% measurement range.
Sulfur Dioxide A Western

Research

Model 721M SO2 analyzer

provided

continuous

analysis

of SO2 in the gas stream.

The basic analytical

principle

involves

quantitative

measurement

of the absorption of UV radiation

by •..•u2 which em•s an appropriate

wavelen•h,

illuminating

the sample

cell through

which the sample is continuously

passed.

Na•ow-band

opti•l

filters are rotated

through

the beam, and the radiation

passed

through

the optical filtem and sample

cell is detected by a single photodetector.

The signal pulses from the photodetector

are separated

by

a multiplexor

into a measuring

channel

and a reference

channel.

A log ratio amplifier compu•th• Iogbri•hm

of the input signal ration, producing

a signal that is pmpo•ional to the SQ• concentration.

The dual-range

analyzer

has a digital readout,

as well as 0- 10.0"V DC output te•inals.

The full s•le of the instrument

was set at 100 ppm.
Carbon Monoxide The CO emissions

were measured

using a Siemens

Ultramat

23 analyzer.

This monitor is a selective

non-dispersive

infrared

radiation

(NDIR) gas analyzer

that operates

on the infrared double-beam

alternating

light principle.

The full range for the CO component

of this instrument

throughout

the test pedod was 1000 ppm.
Total Hydrocarbon

(VOC's) Total hydrocarbons

were continuously

measured

using a California

Analytical

Model 300 flame ionization

detector.

A sample

was extracted

from the source

being tested through i'a heated

sample

line ahd pumped

into a flank6, ionization

detector.

An electrometer coupled

with a potentiometer

recorder

detected

the increase

in ion intensity resulting

from the introduction

into a hydrogen

flame of a sample

of air containing organic

compounds.

The analyzer

was calibrated

using propane.

The analyzer has a digital readout,

as well as 0-10 volt output terminals.

The full scale of theinstrument was set at 100 ppm throughout

the duration

of the test period.

Test results
were reported

as carbon. Sam=}lina System Samples were extracted

from the gas stream

by a heated

stainless

steel probe maintained at a set temperature

of 250 degrees

Fahrenheit,

through

a ten (10) foot heated sample

line that was heated

to a temperature

between

225 and 250 degrees, through a chilled

sample

conditioner

to remove

the moisture

in the gas stream

and

Data Acquisition Concentration

values

were collected

using a Baldwin

Environmental

RM Plus Parametrics data acquisition

system.

The data was recorded

every fifteen-seconds

and then averaged

for e•'•h sixty-second

interval.

Each minute

average

was then averaged for the d0ration

of •ach test run.

; During all testing,

the unit was operating

within normal

operating

parameters;

at a range appropriate in accordance

with applicable

permits.