6oP-.R-i?__ 51 zloL

Exhaust Emissions

Sampling Boral Bricks,

Marshall.

TX Tunnel Kiln Exhaust March 12, 2002 Armstrong Environmental,

Inc. Project W-2193-02

Report Prepared

For: David Johnson Boral Bricks,

Inc. 100 Brickyard

Rd. Phenix City, AL 36869

Report Prepared

March 29, 2002 By: Armstrong Environmental,

.Inc. 7715 Sovereign

Row Dallas, Texas 75247 (214) 631-0021TABLE OF CONTENTS

I, Introduction II. Summary ]JI. Procedures YV. Appendices A. Calculation

Summaries B. Analytical

Summaries C. Field Data Sheets D. Equipment

Calibrations Page 1 2-3. 4

5-7 8 32 34 36 36-38I. INTRODUCTION A series of tests was performed

on the exhaust associated

with Tunnel Kilt• at the Boral Bricks, Inc. facility in Marshall,

TX on March 12, 2002. The purpose

of this test series was to determine

the exhaust emission

rate of Hydrogen Fluoride and Hydrogen

Chloride

in terms of lbs/hr. Testing followed

procedures

detailed

in Title 40: Code of Federal Regulations

(40:CFR). Sampling was performed

by Richard

Taylor and Tom Armstrong

of Armstrong Environmental, Inc. using an Apex Method

5 sampling

train. Three one hour test repetitions

were performed,

commencing

at 9:20 AM and ending at 1:08 PM. Submitted by:II. SUMMARY A series of tests was performed

on the exhaust associated

with the Tunnel Kiln at the Boral Bricks, Inc. facility in Marshall,

TX on March 12, 2002. Sampling was performed

following

procedures

detailed

in Title 40: Code of Federal Regulations. Results of this test series are summarized

in Table 1. Results indicate

the following

emissions

rates: HF, lbs•

3.795

3.637

3.986

3.806 HC1, lbs•

0.264

0.208

0.234

0.235SUMMARY OF EMISSIONS

TEST DATA Table 1 Plant Boral Brick, Marshall,

TX Location Tunnel Kiln Exhaust Operator T. Armstrong,

R. Taylor Test Date 12-Mar-02 Repetition 1 3 STACK GAS Temperature, F 270.7 268.8 268.8 Velocity, fps 50.49 51.27 50.64 Volume Flow, acfm 13894.5 14110.3 13938.3 scfm 9381o0 9468.3, 9354.3 scfh 562859 568097 561260 Moisture, % 5.96% 6.78% 6.77% C02,"% 2.00 2.50 2.50 02, % 17.50 17.00 17.00
9:20 AM 10:25 AM 39.809 97.55472

11:55 AM 12:00 PM 40.084 97.32402 SAMPLE Start Time, hrs:min Finish Time, hrs:min Sample Volume,

scf Isokinetic Ratio, %
121.73 129.8624 3.795131 116.37 123.2916 3.636631 HYDROGEN FLUORIDE Sample Weight, mg Concentration, ppm Emissions, Ibs/hr
8.46 4.944138 0.263692 6.67 3.871598 0.20841 HYDROGEN CHLORIDE Sample Weight, mg Concentration, ppm Emissions, Ibs/hr 12:05 PM 1:08 PM 39.294 96.56688
126.55 136.7742 3.98577

7.42 4.392457 0.233603

3III. PROCEDURES The procedure

for emissions

sampling

followed

USEPA

test methods

as detailed

in Title 40: Code of Federal Regulations.

The following

methods

were used: Method Title Sample and Velocity

Traverses

for Stationary

Sources 2 Determination

of Stack Gas Velocity

and Volumetric

Flow Rate (Type S Pitot Tube) Gas Analysis

for CO2, 02, Excess Air and Dry Molecular

Weight 26A Determination

of Hydrogen

Halides and Halogens

Emissions

from Stationary Sources 02 and CO2 were determined

using FyRite Analyzers.
HF and HC1 sampling

was performed

for 2.5 minutes

at each of 24 points, 12 points per traverse, making

a total run duration

of 60 minutes.

A sdhematic

of the sampling

location is shown in Appendix

C. The sampling

train was configured

as follows: Glass Sampling

Nozzle Heated Glass Lined Probe Heated teflon filter Impinger #1 100 mls 0.1 N H2SO4 Impinger #2 100 mls 0.1 N H2SO4 Impinger #3 Empty Impinger #4 200 grams silica Gel HF and HC1 analysis

was performed

on the solution

from the 1 st and 2nd impingers. Analysis was performed

using a Dionex 500DX IC/HPLC.

4/ kAEMISSION TEST SUMMARY
PLANT Boral Brick, Marshall, TX DATE 12-Mar-02 PLACE Tunnel Kiln Exhaust RUN# TEST DURATION

(MINUTES) NOZZLE DIAMETER (INCH.) METER COEFFICIENT

(Y) PITOT COEFFICIENT

(Cp) GAS METER VOL.(Cu.Ft.) BAROMETRIC PRESSURE 6O 0,247 0.991 0.84 39,767 29.75 LIQUID COLLECTED

(mls) PARTICULATE WEIGHT (Front half mg) PARTICULATE WEIGHT (Back half mg) STATIC PRESSURE (in. H20) PERCENT C02 PERCENT 02 PERCENT CO FOR CIRCULAR STACK STACK DIAMETER (inch): STACK AREA (Sq.Ft.) NOZZLE AREA (feet): FOR RECTANGULAR

STACK 29 STACK LENGTH(inchs) 4.586944 STACK WIDTH(inchs) 0.000333 STACK AREA (Sq.Ft.)
ENTER THE STACK AREA SHOWN ABOVE:

4.586944 FLOWS SAMPLED VOLUME (STD. CU.FT.): VOLUME OF WATER VAPOR (STD. CU.FT.): FRACTIONAL MOISTURE CONTENT (%): DRY BASE: MOLECULAR WT. OF STACK GAS (DRY BASE): MOLECULAR WT. OF STACK GAS (WET BASE):

39.8088 2.5230 0.0596 80.5000 29.0200 28.3632 STACK PRESSURE

(inch Hg): STACK GAS VELOCITY (ft/sec.): ACTUAL STACK GAS FLOW RATE (ACFM): STANDARD STACK GAS FLOW RATE (SCFH):

29.7279 50.4856 13894.4851 562859.058 ISOKINETIC RATIO (%): 97.5547 53.600 -0.32 17.50

POINTS STACK T. DELTA P SQUAR D.P deg F272

0.48 0.69282 2 274

0.61 0.781025 3 275

0.68 0.824621 4 277

0.75 0.866025 5 278

0.76 0.87178 6 277

0.78 0.883176 7 278

0.58 0.761577 8 277

0.55 0.74162 9 276

0.47 0.685565 10 278

0,45 0.67082 11 263

0.36

0.6 12 249

0.27 0.519615 13 262

0.50 0.707107 14 267

0.65 0,806226 15 268

0.71 0.842615 16 268

0,77 0.877496 17 270

0.78 0.883176 18 277

0.75 0.866025 19 269

0.71 0.842615 20 270

0.64

0.8 21 270

0.58 0.761577 22 269

0,52 0.72111 23 275

0.37 0.608276 24 258

0.26 0.509902

DELTA H
0,92 1.20 1.30 1.40 1.50 1.50 1.10 1.10 0.90 0,86 0.70 0.52 0,96 1.20 1.40 1,50 1.50 1.40 1,40 1.20 1.10 1,00 0.71 0.50 METER Y. INLET 566162 6464 656565 6565 6564 6t64 6566 67 676767 676767 67 METER T. OUTLET 52 5353 5454 55 5656 57 575758 58 58 60 595959 5959 6060 6O6O METER T. AVERAGE 270.70833 0.7552

1.1196

64.7083

57.2083

60.9583 5EMISSION TEST SUMMARY
PLANT Boral Brick, Marshall, TX DATE 12.Mar-02 PLACE Tunnel Kiln Exhaust RUN# 2 TEST DURATION

(MINUTES) NOZZLE DIAMETER (INCH.) METER COEFFICIENT

(Y) PITOT COEFFICIENT

(Cp) GAS METER VOL(Cu.Ft.) BAROMETRIC PRESSURE 60 0,247 0,991 0.84 40,428 29.75 LIQUID COLLECTED

(mls) PARTICULATE WEIGHT (Front half mg) PARTICULATE WEIGHT (Back half mg) STATIC PRESSURE (in. H20) PERCENT C02 PERCENT 02 PERCENT CO FOR CIRCULAR STACK STACK DIAMETER (inch): STACK AREA (Sq.Ft.) NOZZLE AREA (feet): FOR RECTANGULAR

STACK 29 STACK LENGTH(inches) 4.586944 STACK WIDTH(inches) 0.000333 STACK AREA (Sq.Ft.)
ENTER THE STACK AREA SHOWN ABOVE:

4.586944 FLOWS SAMPLED VOLUME (STD. CU.FT.): VOLUME OF WATER VAPOR (STD. CU.FT.): FRACTIONAL MOISTURE CONTENT (%): DRY BASE: MOLECULAR WT. OF STACK GAS (DRY BASE): MOLECULAR WT. OF STACK GAS (WET BASE):

40.0841 2.9136 0.0678 80.5000 29.0800 28.3292 STACK PRESSURE

(inch Hg): STACK GAS VELOCITY (ft/sec.): ACTUAL STACK GAS FLOW RATE (ACFM): STANDARD STACK GAS FLOW RATE (SCFH):

29.7279 51.2697 14110.2699 568096.502 ISOKINETIC RATIO (%): 97.3240 61.900 -0.3 2,5170

POINTS STACK T. DELTA P SQUAR D.P degF 268

0,50 0.707107 2 271

0.59 0.768115 3 274

0.71 0.842615 4 273

0.74 0.860233 5 267

0.78 0.883176 6 269

0.77 0.877496 7 268

0.61 0.781025 8 268

0.53 0.728011 9 268

0.47 0.685565 10 267

0.43 0.655744 11 265

0.36

0.6 12 261

0.27 0.519615 13 263

0.52 0.72111 14 269

0.67 0.818535 15 269

0.75 0.866025 16 268

0,81

0.9 17 269

0.77 0.877496 18 271

0.75 0.866025 19 271

0.68 0.824621 20 274

0.65 0.806226 21 271

0.62 0.787401 22 272

0.55 0.74162 23 270

0.48 0.69282 24 266

0.37 0.608276

DELTA H
0.96 1.10 1.40 1,40 1,50 1,50 1.20 1,00 0:90 0,82 0.69 0,52 1,00 1.30 1.40 1,60 1.50 1.40 1,30 1.20 1.20 1.10 0,92 0.72 METER T. INLET 6O 66 68 6969 69 6969 696969 696970 71727272 72727272 72 72 METER T. OUTLET 59 6O 60 60 6161616162 62 62 6262 636363 6464_ 64 64 64 64 6565 METER T. AVERAGE 268.83333 0.7675

1.1513

69.7083

62.3333

66.0208EMISSION TEST SUMMARY
PLANT Boral Brick, Marshall, TX DATE 12-Mar-02 PLACE Tunnel Kiln Exhaust RUN# 3 TEST DURATION

(MINUTES) NOZZLE DIAMETER (INCH,) METER COEFFICIENT

(Y) PITOT COEFFICIENT

(Cp) GAS METER VOL.(Cu.Ft.) BAROMETRIC PRESSURE 60 LIQUID COLLECTED

(mts) 0,247 PARTICULATE

WEIGHT (Front half mg) 0.991 PARTICULATE

WEIGHT (Back half mg) 0.84 STATIC PRESSURE (in. H20) 39,947 PERCENT C02 29.75 PERCENT 02 PERCENT CO FOR CIRCULAR STACK STACK DIAMETER (inch): STACK AREA (Sq.Ft.) NOZZLE AREA (feet): FOR RECTANGULAR

STACK 29 STACK LENGTH(inchs) 4.586944 STACK WIDTH(inchs) 0.000333 STACK AREA (Sq.Ft.)
ENTER THE STACK AREA SHOWN ABOVE:

4.586944 FLOWS SAMPLED VOLUME (STD. CU.FT.): VOLUME OF WATER VAPOR (STD. CU.FT.): FRACTIONAL MOISTURE CONTENT (%): DRY BASE: MOLECULAR WT. OF STACK GAS (DRY BASE): MOLECULAR WT. OF STACK GAS (WET BASE):

39.2937 2.8524 0.0677 80.5000 29.0800 28.3301 STACK PRESSURE

(inch Hg): STACK GAS VELOCITY (ft/sec.): ACTUAL STACK GAS FLOW RATE (ACFM): STANDARD STACK GAS FLOW RATE (SCFH):

29.7265 50.6449 13938.3307 561260.163 ISOKINETIC RATIO (%): 96.5669 60.600 -0.32 2,5170

POINTS STACK T. DELTA P SQUAR D.P degF 268

0.54 0.734847 2 272

0.60 0.774597 3 271

0.70 0.83666 4 274

0.71 0.842615 5 271

0.77 0.877496 6 272

0.76 0.87178 7 273

0,61 0.781025 8 273

0.52 0.72111 9 272

0.47 0.685565 10 272

0,42 0.648074 11 269

0.35 0.591608 12 262

0.27 0.519615 13 265

0.51 0.714143 14 267

0.65 0.806226 15 267

0.72 0.848528 16 268

0.76 0.87178 17 268

0.75 0.866025 18 269

0.73 0.8544 19 269

0.70 0.83666 20 268

0.65 0.806226 21 267

0.59 0,768115 22 266

0.51 0.714143 23 269

0.40 0.632456 24 258

0.35 0.591608

DELTA H

1.00 1.20 1.30 1.40 1,50 1,50 1,20 1,00 0.90 0,80 0.65 0.52 0,98 1,30 1.40 1,50 1.40 1,40 1,30 1.20 1.20 0,98 0.77 0,67 METER T. INLET 6771737374 74 74 74 737373 73 71 74 75757676 7676 76767676 METER T. OUTLET 64 6465 6565 65 6666 66 666666 6767 676767 67 68 68 6868 6868 METER T. AVERAGE 268.75 0.7581

1.1278

73,9583

66.4167

70.1875Sheet1 Summary of Hydrogen

Fluoride

and Hydrogen

Chloride

Analysis Plant: Boral Brick, Marshall,

TX Location: Tunnel Kiln Date: 3/12/02i Volume 1 300 300 1 300 300

2 300 2 300 2 300 21 300
3- 300 Run #

3 300 3 300 3 30• Dilution

FI-, ug/ml 10 39.03 10 38.47 10 38.11 10 38.53 Average 10 36.3 10 36.82 10 36.73 10 37.5 Average 10 39.47 10 39.46 10 40.31 10 41 Average HF, mg 123.2958 121.5267 120.3895 121.7163 121.7321 114.6717 116.3144 116.0301 118.4625 116.3697 124.6857 124.6541 127.3393 129.519 126.5495 CI-, ug/ml HCI, mg 3.49 10.76316 2.94 9.06696 2 6.168 2.54 7.83336 8.45787 2.82 8.69688 1.85 5.7054 2.05 6.3222 1.93 5.95212 6.66915 2.43 7.49412! 2.79 8.60436 1.8 5.5512 2.6 8.0184 7.41702

PageComditioas • 5 ug/mi

El- ; 5 ug/ml

ClDate = 03/16/2002 Ti•e : 10=19=45 -102.40bmV 1024 O00mV Rete•t•0n

.................................................. •rea

I' 317.60 l

4. ,76 4FICIConditions

• 5 u•/ml

F1- Date ': 03/1672002 Time 10=23:38 --i00. O00mV 106'0. OOOrnV Retention

i ,,,i,.,, :I

t0• •Ou•Tml

C•- Time : i0=33=05 Component

C1- -1-00. OOOmV I000 .-O00mV Retention,

,.,•2: ::::::::!'m;;m':'' External

10.00 I0;00

11Conditions : 10 ug/ml
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Cl Date. • 03/16/2002 Time • 10:37:11
CoI•pOnent ZOOO..OOOmV

12condi%ions Date

Component 9eOmV :ooo. oeon:v Retention E•tetnal

13COnd•Lion• = 25 ug/mi

FL-

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C•- Dete = 03/16/2002 Time : I0:46=42 Compon•nf•

FICl- -100.000mV Retent•6•

1 1,216 1000

2110;•0 1643,55

External

1.4Coffditio,n• :. 50 uo•ml

FI- : 50 uo/ml

Cl-. Date : 03/16/2002 Tl•e : 10:54:O8
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FI- -;1,OO. OOOmV :LOO0,000mV Re•e•tio

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I' 4286,27 204:6•35

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C1 O•e : 03/16/2002 Time : I0:58=37 Co•ponen• External

50,89 51,38•alibrati•h file
AMOUNJINJ•OTEOAREA 0. OOO 50. 000 • • t,,,l::::•

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4•2S Z801 ':..::,! Av9 slope

of curve=

85.23 Y-axis •nte•cept•

0.00 Coeff of fin •eg•,•

0,96 No. A.•- ea

Amount

CF .Of O.O00

0 000 i•. 425.300

B.O00 2=. 836.750

iO.O'O0 3; 2L•2.550

25.000 4.• 4325.%80

50.000

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1.7Calibration f&le = CIL.cal

AMOUNT IN3ECTED. AREA 0 •000 50,000

I

2eeo BoSl
Y-a.xi• intercept• Coef• of fin regr: No. ATea

Am-ount o: 0.0•0

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5.•00 2: 637.800

Eo.ooo 3: 1606.025

25.000 4.: 2880•60"5

5Q.O00

CF. 0.000 66-..680" 63.7•0 6g.241 57.612

4

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= •5 ug/ml.

C1- •ate = 03/$6/2002

2107.00 1644,75CoNditions : hi2S04

8!ank Date = 03/16/2002 Time
Com, ponent Area

Exterl•alconditions : Boral.Bricks• Marshall,

TX : Run #1 Imps I & 2 :. Volume

300 Dilution Date : 03/16/2002 Time i$:46:59
Component

FICl- -1 O0 O00m.V iO00 O00mV Retentio•

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i

3354.21 232.76

ExternalConditions = Boral-8{icks, Marshall,

TX : Run •1 Imps I & 2 Qolume 300 Dilution

I/i0 Date : 03/16/2002 Time 11:49:56 Oo•pon•nt

CI3304.75 195,85

Exter#al

382Conditio• : Boral

Bricks,

H•r•hail,

TX Run #i Imps i & 2 : Volume

300 Dilution

I/i0. Oate = 03/16/2002 T•me 11:59:02

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1/10 Date : 03/16/2002 Time : 12:12:00
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3309.59 •69.34

74Condition• : 8orai

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t/10 Date : 03/16/2002

Component -100,000mV 1000,000mV Ret•nti°r"" L.,,:
1,2501. :: ................................................................... 1,70031

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1/10 Date : O3/16/,2OO2 Time : .i2:25:.06
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11i0 Date.: 03/16/2OO2 Time 12;•32:31

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3218.64 128;74

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FICI100. O00mV 1000. O00mV
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1/10 Date : 03/1672002 Time I2:45:19

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External

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TX =Run #3 Imps 1 & 2 : Volume

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1/10 Date : 0"3/16/2002 Time : 12=53:58
Component -i•O0, O00mV Retention.

,266 ,7002 3528,36 173,i2

External
41,00 2,60

32Ap •x C#4#5#6I-M-PINGERS Initial #2 I¢o #3 0

CO__! Z•; o LO3.,ff

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J•5o•<'7l I.Armstrong Environmental

Inc. SPA Method 522 Series Meter Box Calibration Ere-Test Orifice Method E•ullsh Meter Box 0tits, EnGlish Factor Meter Box 30 11/02/01 Serial 30272

Barometric Pressure: 29.80 (i•. Hg) Theoretical Critical Vacuum:--->

14.06 (in. Hq)

METER READINGS
Volume Volume Volume Initial Temps,

Einal Temps.

Orifice K' Orifice Actual A•blent Temperature dR Time Initial Final Total Inlet Outlet

Inlet

Outlet Serial# Coefficient

Vacuum Initial Fi.nal Average [in M20) {•n) (cuft) (c• ft) (cuft) (des F) (des F) Ides F) (deg F) (number) (see above) (in Mg) Ides F) (des F) (des F) 0.24 5.75 635.900 637.761 1.861 81.0 81.0 81.0

81.0 40 0.242 22.0 80.0 80.0 80.0 0.49 6.00 638.100 640.836 2.736 81.0 81.0 81.0

81.0

0.344 20,0 80.0 81.0 80.5 0.90 6.50 641.300 645,312 4.012 81.0 81.0 82.0

81.0 55 0,464 18.0 81.0 80.0 80.5 1.55 7.00 645.800 651.336 5.536 82.0 81.0 83.0

82.0 63 0.593 16.0 81.0 81.0 81.0 2.95 5.00 652.000 657.426

5.426 83.0 82.0 85.0

82.0 73 0.824 14.5 81.0 81.0 81.0

Average y --•--> DRY METER ORIFICE VOLUME VOLUME

VOLUME VOLUME VOLUME

CALIBRATION FACTOR

CALIBRATION FACTOR CORRECTED -•ORR•CTED

CORRECTED CORRECTED NOMINAL

y Vm(std) Vm(std)

Vcr(std)

(std)

Value Variation

Value Variation (cuft) {llter•)

(cuft) (liters) (cuft)

(number) (number)

fin E20) (in M20) 1.809 0.i

1.787

0.i 1.835

0.987

-0. 004

1.359 -0.0482 2.662 0.1

..648 0.1 2.723.

0.995

0.003

1.376 -0.032 3.905 0,2

3.865

0.2 3.974

0.990

-0. 002

1.392 -0.016 5.390 0.2

5.322

0.2 5.477

0.987

-0.0.04

1.465 0,058 5.291 0.2

5.277

0.2 5.431

0.997

0,006

1.445 0.038 0,991 1.407

Average

For Calibration Factor Y, the ratio of the reading of the calibration

the dry meter, acceptable tolerance of individual values from •he average is +-0.02. Orifice Calibration Factor •, •t•e orifice differential

/•essure in inches of •0 t•t •ates 0.75 cfm of •-/air 68 a•d ofMeter Box #: Date: Calibrated By: Degrees F Point 1 Point 2 Point 3 Temperature

Meter Calibrations

lO 11/2101R__T.T Emtech Thermo Checker

Probe

Stack

Oven

Exit

Auxiliary 32 31

31

30

31

30 212 211

211

210

211

211 752 750

751

750

751

751

Degrees R Point 1 Point 2 Point 3

Percent Difference
Point 1 Point 2 Point 3

Em•ch Thermo Checker

Probe

S•ck

Oven

Exit Auxilla• 492 491

491

490

491

490 672 671

671

870

871

871 1212 1210

1211

1210

1211

1211

Probe Stack

Oven

Exit Auxilla• 0.203252 0.203252

0.406504

0.203252

0.406504 0.14881 0.14881

0.297619

0.14881

0.14881 0.165017 0.082508

0.165017

0,082508

0.082508