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

16059TABLE 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 4.24.34.44.5 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 Data1.0 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/hrIb/ton -IF Emissions: •ppm Ib/hr Ib/ton Run I 28329 18487 267.79.3 94.59•0 0.94 0.064 301.6 17.37 1.174 Run 2 29468 19338 264.49.3 97.5 12.7 1.39 0.094 314.1 18.93 1.279 Run 3 29737 19498 265.09.3 94.88.C 0.88 0.060 307.6 18.69 .1.263 Averaqe2917! 19109 265.79.3 95.•9.9 1.07 0.07• 307.•] 18.33 1.2392.0 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

23.0 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.

34.0 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

4Determination 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.

55.0 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

LOCATIONFIGURE 1 Redland Brick Cushwa Plant Tunnel Kiln

Stack

Bend to Fan

> 20'

Points on a diameter 23456789101112

Traverse Points 1.03.35.78.6 12.117.3 31.3 36.4 39.9 42.8 45.3 47.5