P,O. Box 598 Addison, TX 75001 (972) 931-7127

SOURCE EMISSIONS

SURVEY OF BORAL BRICKS,

INC. KILN SCRUBBER

INLET DUCT AND OUTLET

STACK

(EPN-K) HENDERSON, TEXAS TNRCC PERMIT

6192
AUGUST 1999

FILE NUMBER

99-199TABLE OF CONTENTS

INTRODUCTION SUMMARY OF RESULTS DISCUSSION OF RESULTS DESCRIPTION OF SAMPLING

LOCATIONS SAMPLING AND ANALYTICAL

PROCEDURES DESCRIPTION OF TESTS APPENDICES A. Location

of Sampling

Points B. Source

Emissions

Calculations C. Calibration

Data D. Field Testing

Data E. Analytical

Data F. Chain of Custody G. Resumes

of Test Personnel PAGE12710131719

99-199SOURCE EMISSIONS

SURVEY BORAL BRICKS,

INC. KILN SCRUBBER

INLET DUCT AND OUTLET

STACK

(EPN-K) HENDERSON, TEXAS FILE NUMBER

99-199

INTRODUCTION

METCO Environmental,

Dallas,

Texas,

conducted

a source

emissions

survey

of Boral Bricks,

Inc., located

in Henderson,

Texas on August

2, 3 and 4, 1999.

The purpose of these tests was to determine

the concentrations

of particulate

matter, hydrogen fluoride,

and sulfur dioxide

being emitted

to the atmosphere

via the Kiln Scrubber Outlet Stack (EPN-K).

The concentrations

of particulate

matter,

hydrogen fluoride, and sulfur dioxide

were also determined

at the Kiln Scrubber

Inlet Duct.
The sampling

followed

the procedures

set forth in the Code of Federal

Regulations, Title 40, Chapter

I, Part 60, Appendix

A, Methods

1, 2, 3B, 4, 5, 6, and 13B; and in the "Sampling

Procedure

Manual,

Texas Air Control

Board,

Revised

July 1985."

99-199 -1-99-199 -2-SUMMARY OF RESULTS Kiln Scrubber

Inlet Duct
Run Number DateTimeStack Flow Rate DSCFM** % Water Vapor-

% Vol. % CO 2 % Vol. % 0 2 % Vol. 108/03/99 1159-1311 40,987 8.442.4

208/03/99 1620-1732 42,063

16.6 % Excess Air @ Sampling

Point 341

322 Stack Temperature

-°F 487

488 Stack Pressure

"Hg Percent Isokinetic Volume Dry Gas Sampled

DSCF* Particulate Matter Concentrations Probe & Filter Catch grains/dscf* grains/cf @ Stack Conditions Ibs/hrgrains/dscf* 29.88 104.9 35.266

0.1144 0.0583 40.18
0.1212 0.0618 42.57 91,509.5 110.1 14.07 grains/cf @ S•ack Conditions Ibs/hr Hydrogen Fluoride

-/•g Hydrogen Fluoride

Concentrations

dry ppm Hydrogen Fluoride

Concentrations

Ibs/hr 7.732.516.4

3 08/04/99 0919-1031 41,173 7.672.316.6339487 29.81 29.93 105.9 107.2 35.302

0.0549 0.0281 19.79
0.0684 0.0351 24.66 97,085.9 116.7 15.30 0.0618 0.0318 21.81
0.0710 0.0365 25.05 100,896.1 104.8 13.46

* 29.92 "Hg, 68°F (760 mm Hg, 20°C) Flow rate measured

atthe Kiln Scrubber

Outlet Stack(EPN-K). 99-199 -3-SUMMARY OF RESULTS
Kiln Scrubber

Inlet Duct
Run Number 1

2

3 Date 08/03/99

08/03/99

08/04/99 Time 0903-1003

1408-1508

0734-0834 Stack Flow Rate- DSCFM* 40,987

42,063

41,173 % Water Vapor-

% Vol. 7.57

8.69

8.41 Sulfur Dioxide

Concentrations

dry ppm

197.4

224.3

199.1 Sulfur Dioxide

Concentrations

Ibs/hr

80.58

93.97

81.65
Flow rate measured

at the Kiln Scrubber

Outlet Stack (EPN-K).

99-199 -4-mEr£Q

SUMMARY OF RESULTS Kiln Scrubber

Outlet Stack (EPN-K)

Run Number DateTimeStack Flow Rate ACFM Stack Flow Rate- DSCFM* % Water Vapor

% Vol. % CO 2 % Vol. % 02 % Vol. % Excess Air @ Sampling

P•oint Stack Temperature

o F Stack Pressure

"Hg Percent Isokinetic Volume Dry Gas Sampled

DSCF* Particulate Matter Emissions Probe & Filter Catch grains/dscf* grains/cf @ Stack Conditions Ibs/hrgrains/dscf* grains/cf @ Stack Conditions Ibs/hr Hydrogen Fluoride

pg Hydrogen Fluoride

Concentrations

dry ppm Hydrogen Fluoride

Concentrations

Ibs/hr

08/03/99 1200-1315 ,79,546 •40,987 ,8.792.3.16.6339,48029.98 105.4 35.037

0.0413 0.0212 14.51
0.0497 0.0255 17.46 34,503.4 41.8 ,5.34

O8/O3/99 1620-1734 81,728 ,.42,063 ,8.082.316.6339.48629.91101.0 34.461

0.0502 0.0257 18.09
0.0589 0.0302 21.22 36,143.8 44.5 .5.84

308/04/99 0919-1034 ,479,843 -41,173 8.4721316.633948229.96 103.1 •34.426

0.0393 0.0202 13.86
0.0454 0.0233 16.02 30,658.2 37.84.85

* 29.92 "Hg, 68°F (760 mm Hg, 20°C) 99-199

-5-SUMMARY OF RESULTS

Kiln Scrubber

Outlet Stack (EPN-K)

Run Number DateTime 08/03/99 0903-1003

208/03/99 1408-1508

08/04/99 0734-0834 Stack Flow Rate DSCFM* 40,987

42,063 % Water Vapor

% Vol. 9.37

9.21

8.59 Sulfur Dioxide

Emissions

dry ppm

193.7

226.6

198.5 Sulfur Dioxide

Emissions

-Ibs/hr 79.07

94.93

81.40 41,173

29.92"Hg, 68°F(760

mm Hg, 20°C)

99-1 99 -6-DISCUSSION OF RESULTS
Kiln Scrubber

Inlet Duct The three tests for particulate

matter

and hydrogen

fluoride

appeared

to be valid representations of the actual emissions

during the tests. All leak checks

performed

on the sampling

train and the pitot tubes showed

no leaks before or after each test. The indicative

parameters

calculated

from the field data were in close agreement. The moisture

percentages

for the three tests were within 6.2 percent

of the mean value. The rates of sampling

for the three tests were within the specified

limits (90 to 110 percent

isokinetic).

The greatest

deviation

from 100 percent

isokinetic

was 7.2 percent.-
The concentrations

(pounds

per hour) of particulate

matter

for the three tests showed a range of -19.8 percent

to +38.4

percent

variation

from the mean value.
The concentrations

(pounds

per hour) of hydrogen

fluoride

for the three tests showed a range of -5.7 percent

to +7.2 percent

variation,

from the mean value.
The three tests for sulfur dioxide

appeared

to be valid representations

of the actual emissions during the tests. All leak checks

performed

on the sampling

train showed no leaks before

or after each test. The indicative

parameters

calculated from the field data were in close agreement.

The moisture

percentages

for the three tests were within

7.9 percent

of the mean value.
The collection

efficiencies

between

the two sulfur dioxide

impingers

in these tests
were very good, indicating

that little, if any, sulfur dioxide

was bypassed.

99-199 -7-rTEEQ

The efficiencies

were as follows:

Run Number 1

2_

3 Impinger #2

98.5

98.0

98.5 Impinger #3

1.5

2.0

1.5
Collection of 90 percent

or more the the sampled

sulfur dioxide

in the first sulfur dioxide impinger

is a verification

of a representative

sample.
The concentrations

(pounds

per hour) of sulfur dioxide

for the three tests showed

a range of -5.6 percent

to + 10.0 percent

variation

from the mean value.
Kiln Scrubber

Oulet Stack The three tests for particulate

matter

and hydrogen

fluoride

appeared

to be valid representations of the actual emissions

during the tests. All leak checks

performed

on the sampling

train and the pitot tubes showed

no leaks before

or after each test. The indicative

parameters

calculated

from the field data were in close agreement. The moisture

percentages

for the three tests were within 4.3 percent

of the mean value. The measured

flow rates (Qs) for the tests were within

1.6 percent

of the
mean value.

The rates of sampling

for the three tests were within the specified limits (90 to 110 percent

isokinetic).

The greatest

deviation

from 100 percent isokinetic was 5.4 percent.

The calculated

emissions

(pounds

per hour) of particulate

matter

for the three tests showed a range of -12.1 percent

to + 16.4 percent

variation

from the mean value.

99-199 -8-The calculated

emissions

(pounds

per hour) of hydrogen

fluoride

for the three tests showed a range of -9.2 percent

to +9.3 percent

variation

from the mean value.
The three tests for sulfur dioxide

appeared

to be valid representations

of the actual emissions during the tests. All leak checks

performed

on the sampling

train showed no leaks before

or after each test. The indicative

parameters

calculated from the field data were in close agreement.

The moisture

percentages

for the three tests were within

5.2 percent

of the mean value.
The collection

efficiencies

between

the two sulfur dioxide

impingers

in these tests
were very good, indicating

that little, if any, sulfur dioxide

was bypassed.
The efficiencies

were as follows:

Run Number 1

_•_

3 Impinger #2

96.7

95.2

94.5 Impinger #3

3.3

4.8

5.5
Collection of 90 percent

or more the the sampled

sulfur dioxide

in the first sulfur dioxide impinger

is a verification

of a representative

sample.
The calculated

emissions

(pounds

per hour) of sulfur dioxide

for the three tests showed a range of -7.1 percent

to + 11.5 percent

variation

from the mean value.

99-199 -9-DESCRIPTION OF SAMPLING

LOCATION
The sampling

location

on the Kiln Scrubber

Inlet Duct is approximately

30 feet above the ground.

The sampling

ports are located

in a transition

zone of the duct.
The sampling

location

on the Kiln Scrubber

Outlet Stack (EPN-K)

is 90 feet 6 inches above the ground.

The sampling

ports are located

40 feet (6.73 stack diameters) downstream from a constriction

in the stack and 6 feet 5 1/2 inches

(1.09 stack diameters) upstream

from the outlet of the stack.

99-199 -10-SAMPLING LOCATION
Kiln Scrubber

Inlet Duct

©©

Not to Scale 99-199 -11-SAMPLING LOCATION
Kiln Scrubber

Outlet Stack (EPN-K)

Not to Scale 99-199 -12-SAMPLING AND ANALYTICAL

PROCEDURES
The sampling

followed

the procedures

set forth in the Code of Federal

Regulations, Title 40, Chapter

I, Part 60, Appendix

A, Methods

1, 2, 3B, 4, 5, 6, and 13B; and in the "Sampling

Procedures

Manual,

Texas Air Control

Board,

Revised

July 1985."

A preliminary

velocity

traverse

was made at the one port on the Inlet Duct, in order to determine

the uniformity

and magnitude

of the flow prior to testing.

Several traverse points were checked

for cyclonic

flow and none was found to be present. A total of three traverse

points were sampled

from the one port.

A preliminary

velocity

traverse

was made at each of the two ports on the Outlet Stack (EPN-K),

in order to determine

the uniformity

and magnitude

of the flow prior to testing.

Several

traverse

points were checked

for cyclonic

flow and none was found to be present.

Twelve

traverse

points were sampled

from each of the two ports for a total of twenty-four

traverse

points.
The sampling

trains were leak-checked

at the nozzle at 15 inches of mercury
vacuum before each test, and again after each test at the highest

vacuum

reading recorded during the test. This was done to predetermine

the possibility

of a diluted sample.

The pitot tube lines were checked

for leaks before and after each test under both a vacuum and a pressure.

The lines were also checked

for clearance

and the manometer was zeroed

before each test.

99-199 -13-An

integrated

orsat sample

was collected

and analyzed

according

to EPA Method 3B during each test. Particulate Matter/Hydrogen Fluoride Triplicate samples

for particulate

matter

and hydrogen

fluoride

were collected

at each of the two sources.

The samples

were taken according

to EPA Methods

1, 2, 3B, 4, 5, and 13B. For each run on the Inlet Duct, samples

of twenty-four

minute duration were taken isokinetically

at each of the three traverse

points for a total sampling time of 72 minutes.

Data was recorded

at four-minute

intervals.

For each run on the Outlet Stack (EPN-K),

samples

of three-minute

duration

were taken isokinetically at each of the twenty-four

traverse

points for a total sampling

time of 72 minutes.

Reagent

blanks

were submitted.
The front-half

of the sampling

train contained

the following

components: Stainless Steel Nozzle Heated Glass Probe @ 248°F

+ 25OF Heated Quartz

Fiber Filter and Teflon Support

@ 248°F

+ 25°F
The back-half

of the sampling

train contained

the following

components: Impinger Number Contents Amount HPLC Water 100 ml
2 HPLC Water 100 ml

Parameter

Collected Particulate Matter

and Hydrogen Fluoride Particulate Matter

and Hydrogen Fluoride

99-199 -14-nqErcQ

3* HPLC Water 100 ml

4 Silica Gel

* Impinger

3 was empty on the Inlet Duct. Hydrogen

Fluoride

and Moisture 200 g

Moisture

Particulate matter

emissions

were calculated

from gravimetric

analysis

using both the front-half

and back-half

collections

of the sampling

train.
The hydrogen

fluoride

samples

were analyzed

by ion chromatography.
Sulfur Dioxide Triplicate samples

for sulfur dioxide

were collected

at both the Inlet Duct and Outlet Stack (EPN-K).

The samples

were taken according

to EPA Methods

3B, 4, and 6; and the "Sampling

Procedures

Manual,

Texas Air Control

Board,

Revised July 1985."

Large impingers

(500 ml), as specified

in EPA Method

8, were used. For each run, samples

of sixty-minute

duration

were taken from the midpoint

of each source.

Data was recorded

at five-minute

intervals.

At the conclusion

of each run, the sampling

train was purged

for fifteen

minutes

with ambient

air at the
same rate at which the sample

was taken.

Reagent

blanks

were submitted.
The "front-half"

of the sampling

train contained

the following

components: Heated Glass Probe @ 248°F

+_25°F Heated Glass Fiber Filter and Glass Support

@ 248°F

+25°F The "back-half"

of the sampling

train contained

the following

components:

99-199 -15-Impinger Number Content8 Amount

Parameter

Collected 1 80% Isopropyl

Alcohol

200 ml

Sulfur Trioxide 2 6% Hydrogen

Peroxide

200 ml

Sulfur Dioxide 3 6% Hydrogen

Peroxide

200 ml

Sulfur Dioxide 4 Empty Moisture 5 Silica Gel 200 g

Moisture
The isopropyl

alcohol

solution

was checked

for hydrogen

peroxide

contamination

and
none was found.
The samples

were analyzed

by barium

perchlorate

titration

using thorin indicator.

99-199 -16-DESCRIPTION OF TESTS
Personnel from METCO

Environmental

arrived

at the plant at 2:00 p.m. on Monday, August 2, 1999.

After meeting

with plant personnel,

the equipment

was moved onto the Kiln Scubber

Inlet Duct and Outlet Stack (EPN-K).

The equipment

was secured for the night and all work was completed

at 5:15 p.m.

On Tuesday,

August

3, work began at 7:00 a.m. The equipment

was prepared

for testing. The first set of tests for sulfur dioxide

on the Kiln Scrubber

Inlet Duct and Outlet Stack (EPN-K)

began at 9:03 a.m. Testing

continued

until the completion

of the second

set of tests at 3:08 p.m. The first set of tests for particulate

matter and hydrogen

fluoride

on the Kiln Scrubber

Inlet Duct and Outlet Stack (EPN-K) began at 11:59 a.m. Testing

continued

until the completion

of the second

set of tests at 5:34 p.m. The samples

were recovered.

The equipment

was secured

for the night and all work was completed

at 6:30 p.m.

On Wednesday,

August

4, 1999, work began at 7:00 a.m. The equipment

was prepared for testing.

The third set of tests for sulfur dioxide

on the Kiln Scrubber Inlet Duct and Outlet Stack (EPN-K)

began at 7:34 a.m. and was completed

at 8:34 a.m. The third set of tests for particulate

matter

and hydrogen

fluoride

on the Kiln Scrubber

Inlet Duct and Outlet Stack (EPN-K)

began at 9:19 a.m. and was completetd at 10:34 a.m.
The equipment

was moved

off of the stacks

and loaded

into the sampling

van. The samples

were recovered

and transported

to METCO

Environmental's

laboratory in Dallas,

Texas,

for analysis

and evaluation.
99-199 -17-Operations at Boral Brick, Kiln Scrubber

Inlet Duct and Outlet Stack (EPN-K), located in Henderson,

Texas,

were completed

at 12:15 p.m. on Wednesday, August 4, 1999.

President
99-199 -18-