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II-1-003 

ENGINEERING EMISSION TESTING 

FOR 

BORAL BRICKS, INC. 

AUGUSTA, GEORGIA 

SEPTEMBER 10-11, 1991 

Submitted By: 

AIR SYSTEMS TESTING, INC. 

P.O. Box 6278 

Marietta, GA 30065 

(404) 426-0447 

BRUCE LAWRIE 
E.P.A. TEST PROCEDURES 

The testing procedures followed were according to Methods 1, 2, 5, 7, 8, 9, and 

13; for location of sampling points; measuring of stack gas velocity and 

volumetric flow rate; determination of particulate concentrations; determination of 

NOX concentrations; determination of SOz emission concentrations; 

determination of opacity ernissions; and determination of fluoride emission 

concentrations. These methods can be found in the Code of Federal 

Regulafions, Title 40, Parts 53-60, revised as of July 1, 1990. 

Method 1, determination of number and location of sampling points, was used to 

calculate the location of the twelve points used on each traverse. 

EPA Method 2 was used to calculate the stack gas velocity and volumetric flow 

rate. The S-type pitot tube on the pitot-probe assembly was fabricated according 

to design criteria in Method 2 that allows a pitot coefficient of 0.84 to be used in 

the calculations. Stack gas temperatures used in the velocity calculations were 

obtained with a type "K" thermocouple and digital thermometer. Leak checks 

were performed on the pitot-manometer assembly after each test and showed 

no leak. 

Method 5, Determination of Particulate Emission Concentrations, was used to 

determine particulate emissions. The sampling train consisted of a calibrated 

nozzle, ,

union, heated glass liner, glass fiber filter and filter holder, four 

impingers, umbilical cord, pump, and control console. Impinger outlet and dry 

gas meter temperatures were monitored throughout the test with type "K" 

thermocouples. The dry gas meter in the control console was calibrated against 

a Rockwell S-415 test meter that had been standardized with a Rockwell #1464 

Bell Prover. 

A 

~ Z 
SUMMARY OF TEST RESULTS 

TK-2 - Fluorides 

Test #2 Test #4 

Volume @ Meter (Vm): 26.547 26.035 

Sqrt Delta P: 0.388 0.360 

Sampling Time (min): 45 45 

Barometric Pressure (Pb): 30.05 30.05 

Delta H (H): 1.13 0.99 

Volume in Impingers (mis): 9.5 10.0 

Stack Pressure (Ps): 30.05 30.05 

Stack Temperature (Ts):0 668 662 

Meter Coefficient (Y): 1.007 1.007 

Pitot Coefficient (Cp): 0.84 0.84 

Meter Temperature (Tm): 563 570 

Area Stack (As): 7.47 7.47 

Area Nozzle (An): 0.000524 0.000524 

Percent CO2 (%): 0.0 0.0 

Percent 02 (%): (¢j 21.0 21.0 

Percent N2 (%): 79.0 79.0 

Milligrams Fluoride: 3.3 3.8 

Average 

Molecular Weight Dry (Md): 28.84 28.84 28.84 

Volume Water (Vwstd): 0.45 0.47 0.46 

Volume Gas Sampled (Vmstd): 25.239 24.440 24.840 

Wet Fraction (Bws):J) 0.017 0.019 0.018 

Molecular Weight Wet (Ms): 28.65 28.64 28.64 

Volume Gas Sampled (Vma): 32.357 31.098 31.727 

Stack Gas Velocity, (Vs): 24.54 22.68 23.61 

Volumetric Flowrate (Qs): zd 8,580 7,987 8,284 

Volumetric Flowrate (Qa):*--© 11,000 10,163 10,582 

Grainloading, gr/dscf: 0.002 0.002 0.002 

Fluoride Emission Rate, #/Hour: 0.15 0.16 0.16 

Percent Isokinetic Sampling: 93.2 97.0 95.1 

t 

3 
SUMMARY OF TEST RESULTS 

TK-2 - Particulates 

Test #1 Test #3 

Volume @ Meter (Vm): 25.505 25.384 

Sqrt Defta P: 0.365 0.346 

Sampling Time (min): 45 45 

Barometric Pressure (Pb): 30.05 30.05 

Delta H (H): 1.00 0.90 

Volume in Impingers (mis): 8.5 10.0 

Stack Pressure (Ps): 30.05 30.05 

Stack Temperature (Ts): 673 673 

Meter Coefficient (Y): 1.007 1.007 

Pitot Coefficient (Cp): 0.84 0.84 

Meter Temperature (Tm): 553 570 

Area Stack (As): 7.47 7.47 

Area Nozzle (An): 0.000524 0.000524 

Percent CO2 N: 0.0 0.0 

Percent 02 N: 21.0 21.0 

Percent N2 N: 79.0 79.0 

Milligrams: 11.2 20.0 

Average 

Molecular Weight Dry (Md): 28.84 28.84 28.84 

Volume Water (Vwstd): 0.40 0.47 0.44 

Volume Gas Samp!ed (Vmstd): 24.679 23.824 24.252 

Wet Fraction (Bws): 0.016 0.019 0.018 

Molecular Weight Wet (Ms): 28.67 28.63 28.65 

Volume Gas Sampled (Vma): 31.829 30.832 31.330 

Stack Gas Velocity, (Vs): 23.17 21.98 22.57 

Volumetric Flowrate (Qs): 8,051 7,611 7,831 

Volumetric Flowrate (Qa): 10,384 9,850 10,117 

Grainloading, gr/dscf: 0.007 0.013 0.010 

Emission Rate, #/Hour: 0.48 0.85 0.66 

Percent Isokinetic Sampling: 97.2 99.2 98.2 

`/C 
SUMMARY OF TEST RESULTS 

Plant #5 - Fluorides 

Test #7 Test #8 

Volume @ Meter (Vm): 38.259 38.199 

Sqrt Detta P: 0.701 0.669 

Sampling Time (min): 45 45 

Barometric Pressure (Pb): 30.05 30.05 

Delta H (H): 2.58 2.38 

Volume in Impingers (mis): 41.0 43.0 

Stack Pressure (Ps): 30.05 30.05 

Stack Temperature (Ts): 910 910 

Meter Coefficient (Y): 1.022 1.022 

Pitot Coefficient (Cp): 0.84 0.84 

Meter Temperature (Tm): 578 573 

Area Stack (As): 28.27 28.27 

Area Nozzle (An): 0.000475 0.000475 

Percent CO2 (%): 2.0 2.0 

Percent 02 (°k): 18.0 18.0 

Percent N2 (°k): 80.0 80.0 

Milligrams Fluoride: 43.0 45.0 

Average 

Molecular Weight Dry (Md): 29.04 29.04 29.04 

Volume Water (Vwstd): 1.93 2.02 1.98 

Volume Gas Sampled (Vmstd): 36.086 36.326 36.206 

Wet Fraction (6ws): 0.051 0.053 0.052 

Molecular Weight Wet (Ms): 28.48 28.46 28.47 

Volume Gas Sampled (Vma): 65.235 65.809 65.522 

Stack Gas Velocity, (Vs): 51.91 49.56 50.73 

Volumetric Flowrate (Qs): 48,705 46,401 47,553 

Volumetric Flowrate (Qa): 88,048 84,062 86,055 

Grainloading, gr/dscf: 0.018 0.019 0.019 

Fluoride Emission Rate, #/Hour: 7.68 7.60 7.64 

Percent Isokinetic Sampling: 98.1 103.6 100.8 

S 
SUMMARY OF TEST RESULTS 

Plant #5 - Particulates 

Test #5 Test #6 

Volume @ Meter (Vm): 39.736 39.437 

Sqrt Delta P: 0.700 0.699 

Sampling Time (min): 45 45 

Barometric Pressure (Pb): 30.05 30.05 

Delta H (H): 2.54 2.55 

Volume in Impingers (mis): 37.0 35.0 

Stack Pressure (Ps): 30.05 30.05 

Stack Temperature (Ts): 919 917 

Meter Coefficient (Y): 1.022 1.022 

Pitot Coefficient (Cp): 0.84 0.84 

Meter Temperature (Tm): 578 575 

Area Stack (As): 28.27 28.27 

Area Nozzle (An): 0.000475 0.000475 

Percent CO2 (%): 2.0 2.0 

Percent 02 (%): 18.0 18.0 

Percent N2 (%): 80.0 80.0 

Milligrams: 38.9 29.7 

Average 

Molecular Weight Dry (Md): 29.04 29.04 29.04 

Volume Water (Vwstd): 1.74 1.65 1.69 

Volhame Gas Sampled (Vmstd): 37.475 37.388 37.431 

Wet Fraction (Bws): 0.044 0.042 0.043 

Molecular Weight Wet (Ms): 28.55 28.57 28.56 

Volume Gas Sampled. (Vma): 67.962 67.501 67.732 

Stack Gas Velocity, (Vs): 52.03 51.87 51.95 

Volumetric Flowrate (Qs): 48,661 48,736 48,698 

Volumetric Flowrate (Qa): 88,248 87,988 88,118 

Grainloading, gr/dscf: 0.016 0.012 0.014 

Emission Rate, #/Hour: 6.68 5.12 5.90 

Percent Isokinetic Sampling: 101.9 101.5 101.7 

4- 
SAMPLING PROCEDURES 

The sampling locations for the testing were on a specially constructed platforms 

on the exhaust stacks. A wooden platform was used on each of the test ports to 

support the filter/impinger box while the probe traversed the stack. 

Prior to each test, the sampling train was assembled for testing. An 80% 

isopropanol solution was placed in impinger one, and a 3% hydrogen peroxide 

solution in impingers two and three. 200.0 grams (g) of silica gel was placed in 

impinger number 4. The probe was secured in the sampling box, the filter holder 

assembly was installed, and the system was ready for pre-test leak checks. 

After each test, leak checks were performed on each sampling train and each 

side of the pitot tubes. In each of the test repetitions, all leak checks were within 

the allowable limitations. Next, the train was disassembled. The filter holder was 

removed and sealed to prevent loss of particulate matter. The probe and nozzle 

were cleaned with reagent grade acetone, with all sample exposed' surfaces 

brushed and rinsed at least six times to insure all particulate matter was 

removed. This rinse was saved in a 500 ml polyethylene bottle. Next, the 

contents of impingers two and three were measured with a graduated cylinder, 

and saved for further analysis. The silica gel was returned to its container and 

sealed. 

*N. 

6 7 
Method 8, Determination of Sulfur Dioxide Emissions from Stationary Sources, 

was used to determine S02 concentrations. The particulate test train was 

modified by replacing the distilled water normally used in the first two impingers 

with a 80% isopropanol solution in impinger one, and a 3°k hydrogen peroxide 

solution in impingers two and three. 

Method 13B, Determination of Fluoride Emission Concentrations, was used to 

determine fluoride emissions. The sampling train consisted of a calibrated 

nozzae, union, probe with 316 stainless steel liner heated with 50 feet of 0.4 

ohms per foot of nichrome wire, three impingers, Whatman number one filter and 

filter holder, silica gel impinger, umbilical cord, pump, and control console. 

Impinger outlet and dry gas meter temperatures were monitored throughout the 

test with type "K" thermocouples. The dry gas meter in the control console was 

calibrated against a Rockwell S-415 test meter that had been standardized with 

a Rockwell #1464 Bell Prover. 

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FAX ANb FACTS 

FROM CLEMSON - 

THE CERAMIC CENTER % 

CLEMSON UNIVERSlTY, P. 0. BOX 340908 

CLEMSON, SC 29634-0908 

TEL: 803-656-9094 FAX: 803-656-1095 

DATE 

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BORAL BRICK PLANT #5 - FLUORIDES 

.;olume @ Meter (Vm): 

Test #4 

41.364 

Test #5 

40.379 

Test #6 

40.692 ft^3 

'I Sqrt Delta P: 0.784 0,775 0.770 

bompling Time (min): 60 60 60 min 

Barometric Pressure (Pbar): 30.10 30.10 30.10 inHg 

Avg Delta H: 1.55 1.50 1.46 

Volume in impingers (mis): 62.0 57.7 64.1 mis 

Stack Pressure (Ps): 30.15 30.14 30.13 inHg 

Stack Temperature (Ts): 880 889 883 R 

Meter Coefficient (Y): 0.9874 0.9874 0.9874 

Pitot Coefficient (Cp): 0.84 0.84 0.84 

Meter Temperature (Tm): 554 558 545 R 

Area Stack (As): 28.27 28.27 28,27 ft"2 

Area Noizle (An): 0,000334 0.000334 0.000334 ft^2 

Percent CO2 (%): 2.0 2.0 2.0 % 

Percent 02 (%}; 18.0 18.0 18.0 % 

Percent N2 (%); 80.0 80.0 80.0 % 

Fluoride (mg): 8518 75.9 82.1 mg 

, 

Average 

Molecular Weight Dry (Md): 29.04 29,04 29.04 29.04 Iblibmol 

Volume Water (Vwstd): 2,92 2.71 3.02 2.88 scf 

lume Gas Measured (Vmstd): 39.32 38.10 39.32 38.91 scf 

Wet Fraction (Bws): • 0.0691 0.0665 0.0712 0.0689 

Molecular Weight Wet (Ms): 28.3 28.3 28,3 28.3 Ib/lbmol. 

Volume Gas Sampied (Vma): 68.7 68.3 67,7 68.2 ft^3 

Stack Gas Velocity (Vs): 57.2 56.8 56.3 56.8 -ftls 

Volumetric Flowrate (Qs): , 58216 57260 57151 57542 scfm 

Volumetric Flowrate (Qa): 97054 96441 95595 96363 scfm 

Total HF (mg): 90.35 79.92 86.45 85.57 mg 

HF Concentration(cs): 2.30 2.10 2.20 2.20 mg/dscf 

HF Emissions rate (pmr): 17.69 15.89 16.62 16.73 lb/h 

Percent Isokinetic Sampling: 101.7 100.0 103.9 101.9 % 

/1 
' BORAL BRICK PLANT n5 - CHLORIDES 

Test #4 Test #5 Test #6 

~ 

/olume @ Meter (Vm): 41.364 40.379 40.692 ft^3 

~ Sqrt Delta P: 0,784 0.775 0.770 

3ainpling Time (min): 60 60 60 min 

3arometric Pressure (Pbar): 30,10 30.10 30.10 'snHg 

avg Delta H: 1.55 1.50 . 1.4fi 

Jolume in impingers (mis): 62.0 57.7 64.1 mis 

3tack Pressure (Ps): 30.15 30.14 30.13 inHg 

~ tack Temperature (Ts): 9 880 889 883 R 

Vleter Coefficient (Y): 0,9874 0.9874 0.9874 

'itot Coefficient (Cp): 0.84 0.84 0.84 

Vleter Temperature (Tm): 554 558 545 R 

4rea Stack (As): 28.27 28.27 28.27 ft^2 

4rea Nozzle (An): 0,000334 0.000334 0.000334 ft^2 

?ercent CO2 (%): 2.0 2.0 210 % 

Percent 02 (%): 8 18.0 18,0 18.0 % 

Percent N2 (%): 80.0 80.0 80,0 % 

"".'hloride (mg): 42.9 38.1 40.4 mg. 

Vlolecular Weight Dry (Md); 29.04 29.04 29.04 

Jolume Water (Vwstd): 2.92 2.71 3.02 

+" ime Gas IVMeasured (Vmstd): 39.32 38.10 39.32 

1Vet Fraction (Bws): 7 0.0691 0,0665 0,0712 

Vfolecular Weight Wet (Ms): 28.3 28,3 28.3 

Jolume Gas Sampled (Vma): 68.7 68.3 67.7 

~ tack Gas Velocity (Vs): 57.2 56,8 56.3 

Jolumetric Flowrate (Qs): 66 58216 57260 57151 

Jolumetric Flowrate (Qa): 6 a 97054 96441 95595 

i'otal HCI (mg): 44:10 39.17 41.53 

-iCl Concentration (cs): 1,12 1.03 1.06 

1Cl Emissions rate (pmr): 8.64 7.79 7,99 

'ercent lsokinetic Sampling: 101.7 100.0 103.9 

Average 

29.04 Ib/lbmol 

2.88 scf 

38.91 scf 

0.0689 

28.3 lb/(bmol 

68.2 ft^3 

56.8 ftJs 

57542 scfm 

96363 xcfm 

41.60 mg 

9.07 mgldscf 

8.14 Ib/h 

't01.9 % 

_•. 

/ Z.