FINAL REPORT 

HYDROCHLORIC ACID AND HYDROGEN FLUORIDE 

TUNNEL KILN 

CUSHWA PLANT 

REDLAND BRICK, INC 

WlLLIAMSPORT, MARYLAND 

PROJECT 1107 

APRIL 29, 2005 

PREPARED BY 

ALEX KEFFALAS 

PROJECT ENGINEER 

BLUE MOUNTAIN ENVIRONMENTAL MANAGEMENT CORPORATION 

1191 PITTSBURGH ROAD 

VALENCIA, PENNSYLVANIA 16059 
TABLE OF CONTENTS 

i .0 EXECUTIVE SUMMARY 1 

SCOPE AND OBJECTIVES 2 

PROCESS DESCRIPTION 3 

4.0 PROCEDURES 4 

4.•. F!e!d Work 4 

4.1.2 

4.1.3 

4.1.4 

4.1.5 

Field Data Sheets 4 

Emission Testing Station and Traverse Locations 4 

Determination of Gas Flow and Gas Temperature 4 

Determination of Carbon Dioxide and Oxygen 4 

Determination of Moisture Content 4 

4.1.6 Determination of Hydrochloric Acid and Hydrogen Fluoride 

Emissions 5 

4.1.7 Sample Recovery Procedure 5 

4.2 

4.3 

4.4 

4.5 

Laboratory Analyses 5 

Calculations 5 

Field Equipment Calibrations 5 

Process Data 5 

5.0 SUMMARY OF RESULTS 6 

FIGURES 

Figure t Outlet Stack Sampling Location 

APPENDICES 

Appendix A 

Appendix B 

Appendix C 

Appendix D 

Appendix E 

Field Data Sheets 

Laboratory Report 

Ca!cu!ations 

Field Equipment Calibrations 

Process Data 
1.0 EXECUTIVE SUMMARY 

Redland Brick, Inc_. (Red!and Brick) contracted Blue Mountain Environmental Management Corporation (Blue Mountain) to conduct a hydrochloric acid (HC1) and hydrogen fluoride (HF). emissions evaluation of the Cushwa Plant Tunnel Kiln located in Williamsport, Maryland. Sampling and analyses were conducted using the principles of U.S. Environmental Protection 

Agency (EPA) methods specified in 40 CFR, Part 60, Appendix A. 

Table 1 presents a summary of the HC1 and HF emission sampling results. 

TABLE 1 

EMISSION SUMMARY 

Parameter 

Gas flow, acfm 

Gas flow, dscfm 

Gas temperature, °F 

Gas moisture, % by volume 

Isokineti.c ratio, % 

HCl Emissions: 

ppm 

Ib/hr 

Ib/ton 

-IF Emissions: 

•ppm 

Ib/hr 

Ib/ton 

Run I 

28329 

18487 

267.7 

9.3 

94.5 

9•0 

0.94 

0.064 

301.6 

17.37 

1.174 

Run 2 

29468 

19338 

264.4 

9.3 

97.5 

12.7 

1.39 

0.094 

314.1 

18.93 

1.279 

Run 3 

29737 

19498 

265.0 

9.3 

94.8 

8.C 

0.88 

0.060 

307.6 

18.69 

.1.263 

Averaqe 

2917! 

19109 

265.7 

9.3 

95.• 

9.9 

1.07 

0.07• 

307.•] 

18.33 

1.239 
2.0 SCOPE AND OBJECTIVES 

The scope of t_his project was to determine HC1 and HF emissions from the Cushwa Plant Tunnel 

Kiln located at the Williamsport Plant using approved reference-sampling methods. The results 

of the test are intended to determine compliance with Maryland Department of the Environment 

(MDOE) regulations. Because the Tunnel Kiln is a steady state process, three 72-minute sample 

runs were conducted in one single day. 

The following parameters were determined at a minimum for each of three test runs: 

• Gas Flow acfm and dscfm 

• Gas Temperature °F 

• Gas Moisture % by volume 

• Sample Gas Volume dscf 

• Isokinetic Ratio % 

• HC1 Emissions ppm, lb/hr and lb/ton 

• HF Emissions ppm, lb/b_r and lb/ton 

Blue Mountain Contact: 

Redland Brick Contact: 

Laboratory Contact: 

Paul Jadlowiec 

Blue Mountain Environmental Management Corporation 

1191 Pittsburgh Road 

Valencia, Pennsylvania 16059 

Telephone: (724) 898-4500 

Facsimile: (724) 898-2908 

Barry Miller 

Redland Brick, Inc. 

PO Box 160 

15718 Clear. Spring Road 

Williamsport, Maryland 21795 

Telephone: (301) 223-7700 

Facsimile: (301) 223-6675 

Nancy Kotsko 

Air Quality Services, Inc. 

4527 Clairton Boulevard 

rmsbtitgn, PA •5z..,o 

Telephone: (412) 881-5630 

2 
3.0 PROCESS DESCRIPTION 

The Cushwa Plant manufactures molded bricks. Shale is mined on-site and is crushed, ground, 

mixed with water, formed in sanded molds, dried to remove moisture, stacked onto kiln ears 

which are transferred into a Lingl natural gas-fired tunnel kiln and heated to a temperature of 

approximately 2000 degrees Fahrenheit. The final product is allowed to cool and then is 

packaged. 

The Lingl Tunnel Kiln has a maximum push rate of..3-1-• cars per day. Exhaust gases from the 

Tunnel Kiln are exhausted to the atmosphere through a dedicated 48.5-inch diameter stack at a 

rate of 29•200 actual cubic feet per minute at 265 degrees Fahrenheit. 

3 
4.0 PROCEDURES 

4,1 FIELD WORK 

4.1,1 Field Data Sheets 

Copies of all field data sheets are contained in Appendix A. 

4.1.2 Emission Testing Stations and Traverse Locations 

The outlet sampling station is located on the roof of the facility. The internal diameter of the 

20 feet or 5.0 diameters from the test ports. The nearest upstream disturbance is greater than 8 

feet or 2.0 diameters from the test ports. EPA Method 1-Sample and Velocity Traverses For 

Stationary Sources was used to determine the number and location of the traverse points. 

Twenty-four (24) sampling points were used, twelve (12) at each of the two test ports that are 

located 90 degrees to center. The sampling points were located from the inner wall of the stack as 

follows based on a 48.5 inch internal stack diameter: 1.0, 3.3, 5.7, 8.6, 12.1, 17.3, 31.3, 36.4, 

39.9, 42.8, 45.3 and 47.5 inches. A drawing of the outlet stack sampling location and a table of 

the traverse points is in Figure 1. 

4.1.3 Determination of Gas Flow and Gas temperature 

The gas flow rate and temperature profiles for the gas stream were measured by conducting 

simultaneous velocity and temperature traverses concurrently with each HC1 and HF emission 

sampling rtm. Gas velocity head was measured with a calibrated "S"-type pitot tube that was 

connected to an inclined manometer. A chrome-alumel thermocouple attached to a digital 

indicator was used to measure the gas temperature at each of the traverse points. The gas flow 

and gas temperature measurements followed the principles of EPA Method 2- Determination of 

Stack Gas Velocity and Volumetric Flow Rate (Type S Pitot Tube). 

An angular flow test was conducted prior to HC1 and HF emission sampling. The average angle 

of flow was 9.0 degrees. 

4,1•4 Determination of Carbon Dioxide and Oxygen 

A Fyrite analyzer was used to determine the molecular weight of the flue gas for the 

measurement of gas flow during each sampling r-an. Three grab samples were •,ll•,•, 

each sample run using the principles of EPA Method 3-Gas Analysis For The Determination Of 

Dry Molecular Weight. The following parameters were measured: percent by volume of carbon 

dioxide (COz), percent by volume (02) and percent nitrogen (N2) was determined by difference. 

4.t.5 Determination of Moisture Content 

Moisture sampling was conducted using the principles presented in EPA Method 4 

4 
Determination of Moisture Content in Stack Gases concurrently with the HC1 and HF emissions 

sampling. Parameters evaluated to determine the gas stream moisture content were: sample gas 

volume, sample gas temperature, sample gas pressure, impinger moisture gain, and Silica gel 

moisture gain. 

4.1.6 Determination of Hydrochloric Acid and Hydrogen Fluoride Emissions 

EPA Method 26A-Determination of Hydkogen Halide and Halogen Emissions from Stationary 

Sources was used in this test program. HC1 and HF in particulate and gaseous form was• 

withdrawn isokinetically from the gas stream and collected using a glass-lined probe, glass 

nozzle and Teflon coated filter. A series of glass impingers containing a 0.1 normal sulfuric acid 

test program and therefore, impingers containing a sodium hydroxide solution were not included. 

A calibrated dry gas meter measured the gas sample volume that exceeded 41 dry standard cubic 

feet for each sample test rtm. The average of three 72-minute sampling rims constituted the test. 

4.1.7 Sample Recovery Procedure 

Recovery of samples was conducted on-site in accordance with EPA Method 26A procedures. 

4.2 LABORATORY ANALYSES 

Air Quality Services, Inc. conducted the HC1 and HF analysis according to EPA Method 26A. A 

copy of the Laboratory Report is contained in Appendix B. 

4.3 CALCULATIONS 

Emission calculations were completed using a computer spreadsheet format. The results of each 

pertinent parameter were detailed on the spreadsheet for each sampling run and are contained in 

Appendix C. A sample calculation is included. 

4.4 FIELD EQUIPMENT CALIBRATIONS 

The following field equipment calibration data are contained in Appendix D: 

Nozzle Diameter Thermocouple 

Dry Gas Meter and Orifice Pitot Tube 

4.5 PROCESS DATA 

Process data is contained in Appendix E. 

5 
5.0 SUMMARY OF RESULTS 

Table ! presents a summary of the HC1 and HF emissions. 

The HC1 emissions ranged from 0.88 lb/hr to 1.39 lb/hr and theaverage emission rate was 1.07 

lb/hr. The HC1 emissions ranged from 0.060 lb/ton of brick produced to 0.094 lb/ton of brick 

produced and the average emission rate was 0.073 lb/ton of brick produced. 

The HF emissions ranged from 17.37 lb/hr to 18.93 lb/hrand the average emission rate v•as 

18.33 lb/hr. The I-IF emissions ranged from 1.174 lb/ton of brick produced to 1.279 lb/ton of 

brick 9roduced and the average emission rate was 1.239 lb/ton of brick produced. 

6 
/ 

RGURE 1 

STACK SAMPLING LOCATION 
FIGURE 1 

Redland Brick 

Cushwa Plant 

Tunnel Kiln Stack 

Bend to Fan 

> 20' 

Points on a diameter 

2 

3 

4 

5 

6 

7 

8 

9 

10 

11 

12 

Traverse Points 

1.0 

3.3 

5.7 

8.6 

12.1 

17.3 

31.3 

36.4 

39.9 

42.8 

45.3 

47.5