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 99-199 
TABLE 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 

PAGE 

1 

2 

7 

10 

13 

17 

19 

99-199 
SOURCE 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 

Date 

Time 

Stack Flow Rate DSCFM** 

% Water Vapor- % Vol. 

% CO 2 % Vol. 

% 0 2 % Vol. 

1 

08/03/99 

1159-1311 

40,987 

8.44 

2.4 

2 

08/03/99 

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/hr 

grains/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 

7.73 

2.5 

16.4 

3 

08/04/99 

0919-1031 

41,173 

7.67 

2.3 

16.6 

339 

487 

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 

Date 

Time 

Stack 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/hr 

grains/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 

,8.79 

2.3 

.16.6 

339 

,480 

29.98 

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 

,8.08 

2.3 

16.6 

339 

.486 

29.91 

101.0 

34.461 

0.0502 

0.0257 

18.09 

0.0589 

0.0302 

21.22 

36,143.8 

44.5 

.5.84 

3 

08/04/99 

0919-1034 

,479,843 

-41,173 

8.47 

213 

16.6 

339 

482 

29.96 

103.1 

•34.426 

0.0393 

0.0202 

13.86 

0.0454 

0.0233 

16.02 

30,658.2 

37.8 

4.85 

* 29.92 "Hg, 68°F (760 mm Hg, 20°C) 

99-199 -5- 
SUMMARY OF RESULTS 

Kiln Scrubber Outlet Stack (EPN-K) 

Run Number 

Date 

Time 

08/03/99 

0903-1003 

2 

08/03/99 

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-