From: "West Martha" <Martha.West@generalshale.com>

To: Jeff Telander/RTP/USEPA/US@EPA

Date: 04/21/2011 02:15 PM

Subject: General Shale Brick - Spring City, TN; 114 Request for Testing

Dear Mr. Telander,

Attached is a testing protocol from Alliance Source Testing for the testing to be performed on May 5th, 

2011 at our Spring City, TN facility.

Please let me know if you have any questions regarding the attached information or the testing plans.

Thank You,

Martha West

Martha West, REM

Environmental Engineer

Office: (423)952-4240

Fax: (423)952-4160

Email: Martha.west@generalshale.com

P.O. Box 3547

Johnson City, TN 37602

(See attached file: 11-0126 General Shale Protocol.doc)
SOURCE TESTING PROTOCOL 

Testing Company 

Alliance Source Testing LLC

214 Central Circle SW

Decatur, AL 35603

AST Project No. 2011-0126

Page 1 of 2

AST Contact Info Facility Name & Contact Info

Project Manager – Chris LeMay

Phone Number – (256) 280-6005

E-mail – chris.lemay@stacktest.com

General Shale Brick, Inc.

241 Hoyal Lane

Spring City, TN 37381

Bill Alvins, Plant Manager – (423) 791-1980

Steve Sanders, Assistant Plant Manager – (423) 365-4028

Field Test Team Leader – Stacey Cunningham*

Phone Number – (256) 426-0055

E-mail – stacey.cunningham@stacktest.com

*Assigned at initial project scheduling, subject to change.

Ms. Martha West

General Shale Brick, Inc.

P.O. Box 3547

Johnson City, TN 37602

Phone Number – (423) 952-4240

Fax Number – (423) 952-4160

E-mail – martha.west@generalshale.com

Applicable Permit Number(s) Specific Source(s) & ID(s)

Tennessee Department of Environment and Conservation

(TDEC) Permit No. 964000P

Kiln/Predryer Consisting of One coal/Natural Gas Fired Brick 

Tunnel Kiln with Dry Injection Fabric Filter Control and One 

Predryer Using Waste Heat from the Kiln

Emission Source Reference No. (ESRN) 72-0116-04

EPA ID’s:

Tunnel Kiln (EU ID: tk-1)

Dry Sorbent Injection/fabric filter (Control/Stack ID: diff-1)

Purpose of Testing (include state/federal regulations as applicable)

The U.S. EPA has requested in Section 114 letter, pursuant to its authority under section 114 of the Clean Air Act, emissions data for 

certain pollutants to develop emission standards for hazardous air pollutants (HAPs).

Industry NAICS: 327129

Process & Control System Description

Brick exterior building material is manufactured at this facility. Shale and clay are mined, crushed and sent through a screening 

process prior to brick forming by extrusion. Once the brick is extruded, it is dried in a tunnel Kiln at temperatures exceeding 1,900 °F. 

After being fired, the brick is cooled, packaged and shipped to various locations. The emissions are controlled with a baghouse. 

Permitted Max

Process Rate

22.83 tph

(20.71 Mg/hr)

Normal Process 

Operating Rate

18.89 tph

(17.14 Mg/hr)

Target Process 

Operating Rate 

for Testing

11.41 tph

(10.35 Mg/lb)

Production/Process/Control System Data to be recorded during testing

• Brick Production, tph & Mg/hr

• Coal Usage, lb/hr

• Baghouse Differential Pressure, in. w.c.

• Sorbent Injection Rate, lb/hr

• Sorbent Type Used
SOURCE TESTING PROTOCOL 

Testing Company 

Alliance Source Testing LLC

214 Central Circle SW

Decatur, AL 35603

AST Project No. 2011-0126

Page 2 of 2

Test Information

Source Target

Pollutant

Proposed

Test Method

Number of

Test Runs

Test Run

Length Comment

Tunnel Kiln

Baghouse 

Volumetric Flow Rate (VFR) 1-2 -- -- Full Velocity Traverses

Oxygen/Carbon Dioxide (O2/CO2) 3A -- -- Integrated Bag/Instrumental Analysis

Moisture Content (BWS) 4 3 60 

minutes Volumetric/Gravimetric Analysis

Particulate Matter (PM) 5 3 60 

minutes Isokinetic Sampling

Hydrogen 

Chloride/Chlorine/Hydrogen 

Fluoride (HCl/Cl2/HF)

26A 3 60 

minutes Isokinetic Sampling

Multiple Metals 

(Sb, Ar, Be, Cd, Cr, Co, Pb, Mn, 

Hg, Ni & Se)

29 3 60 

minutes Isokinetic Sampling

Notes:

All testing will be conducted in accordance with the most recent revisions of U.S. EPA Reference Test Methods unless otherwise 

noted. The proposed sampling locations will meet the minimum U.S. EPA Reference Test Method 1 criteria for acceptable 

measurement sites unless otherwise noted. The absence of cyclonic flow will be verified per U.S. EPA Method 1 prior to testing, 

unless otherwise noted. All testing equipment has been calibrated in accordance with applicable U.S. EPA Reference Test Methods 

and/or upon suggested manufacturer schedule. All applicable calibration gases meet U.S. EPA Protocol 1 standards unless otherwise 

noted. Copies all al calibration data will be included in the final report submittal.

Additional Space provided here for Test Information Comments (include any deviations)

All testing will be conducted simultaneously.

Proposed Test Schedule

Day Date Source Comment

Day 1 5/5/11 Tunnel Kiln 

Baghouse Conduct ICR Testing

Attachments to Source Testing Protocol Form

None