EN TEC

Services Po.ut|on Control System Eyslustton

and Source Emissions

Testing September 19, 2005
Mr. John Jensen Belden Brick Company 475 Dover Road Sugarcreek, OH 44681 Re: Compliance

Testing

for Particulate

and Visible

Emissions Brick Plant No. 8, Tunnel

Kilns t-3 Sugarcreek, Ohio Entec Project No.: 25126
Dear Mr. Jensen, Please find the attached

three copies of the compliance

emissions

testing for the Brick Plant No. 8 performed

at your facility on August 23, 2005. We appreciate

the opportuni•

to perform

this project

for you and hope to be of assistance to you in the future. If you have any questions

please call 205t 491-6676. Sincerely, Entec Services,

Inc.
Erik Groth Project Leader

Fax (205) 491-6614 Commerce Avenue

Hueytown,

Alabama 35023 Phone: (205} 49t-6676 www.entecserv|ces.comENTEC Services,

Inc.
CALCULATED TEST DATA II IIIIIIIII

O•©rl ,•,, Forums

Symbol unrm Run Num•r Test •te Job No•:

2512•

29,24 29•23

29.23 40.9"79 40.214

40.704 3.9t• 3:770

15. Padic•4a• concentration

•.Star•ard Co•d•Jons •:.,_Conde•si.•?.•o•ce•ttali0• @ Standard Corlditiot•s 48•089

48.442

47•341

47,957 4•2,990 43•826

42,g6•

43•25• 0;01 i6 0•0072

0.0• t8 0.0102 -00007 0,0105

•0:0010

0,0030 4.29 2.72

4,35

3.79
73.504 72;942

7•.596

72:681 0•0065 00•'•

0.0066

0,0057 •00•74 98•97

99,08

99.59 V•ume • -•r•h nozzJe 23. pa•iculata o•nce•r•

•L•a• cond•

1.0200

;020•

,01 •2 4.43%ENTEC Services,

Inc.

CALCULATED TEST DATA

Source:

T•r•e Beeps-Ended Stack M•__ele• Pre•suce t2t8-1323

1358-1500

;547;ff•50 •H__,• 29•23

29.24

29:23 Job No•;

25•12• ,Da•a,,h•p•t •B•: Lllan

2 3 08/23•05 0•23t05

29.23 40.979 40,214

40.704 3,911 3,770

3,9•1

{EMC •LT-•I•Laboratory Data Particulate Matter GPavtmetric Anal•isTommy Lot¢ J Tommy Lotz Jr. 29,6B 29.?7 4 4

D|stffied Water Blank

•4

3• 3,707AENTEC Services,

Inc.
INPUT TEST DATA Client: Source: F•d:Oa• •un Number Test Date

Belden Bdck Company ar•k plant N,o,. ,B, Kilns 1-3S•bol r_im•e_Test Run BeUlah Ended Sampling Time StackAma 3arometric Pressure Stack Static Pressure Pitot Tube, •rre¢!!o•,,factor Meter Correction Factor Meter Delta Nozzle Diameter Meter Vo!•mer
•ht

Gain (Moistur..e•• Silica Gel lmpinger Weight Gain (Moisture) Oxygen ConCentration,

dry ;Carbon Dioxide Concentration,

d_d_d_d_• basis iStaok Temperature To!al condensi,bte

par*dcutate co!le, ct,•d ITotal parti¢[da•e collected Units

Job No=: Data •nput B•

0 250 44.159 82.0 1.8189.3
17.5
0.824 364,9 30,9

25126 Lalan Kirby Test Oa• 2 3 08/23/05 08/23/05 1356-1500 •0 21.• 29.i0 0.280.84

0.250 44•194 81.7
83.18,618.0 17•0 3.0 3,0 0,832 0.815 367.2 369.9 28.0 -2.5 19,2 30.8 1547-t650 •o

60 21.648 2•:•:I0 t 29.10 o,• ! 0,28 o• to,84. 0,974 ! 0;974 !.913 1.913 43,423 • 43.925 ae,a I 82.0

7•0 9.817.5
0.824 367.3
21.0EN Pollution Control System Evaluation

and Source Emissions

T•ing Belden Brick

Company Sugarcreek

, Ohio Annual Complian•

Testing Brick PlantNo,8,

Kilns t,3
August 23, 2005 Entec Project No.:26125

lS• Commeme

Average Hueytown,

Atabama 350•3 Phone: (205) 4Sl•S76

Fox (•5) 491•14 www.entecservices•eomEntec Sewices, Inc. 16 D Commerce

Avenue Hue•own, Alabama

35023 Telephone: (205) 491-6676 Fax: (205) 49t-6614 Results of the August

23+ 2005 Compliance Testing

for Particulate

and Visible

Emissions

on the Brick Plant No. 8 Tunnel

Kilns 1-3 located

in Sugarcreek, Ohio Facility Permit

No. 06-79-00-0118,

ID No, P801tPS02/P803 Submitted to: Belden Brick

Company 475 Dover Road Sugarcreek, Ohio •81
Attention: Mr. John Jensen Entec Project No. 25126 Completed By:
Erik Groth Project Leader Report Submitted:

September

19. 2005 Reviewed By:

Tom Lotz Sr. QNQC Manager
hereby certify to the best of my knowledge

all field sampling

and laboratory

analysis performed for this report is authentic

and accurate+

It has been checked for completeness

and accuracy,Belden Brick

Company Table of Co•tents
SectionExecutive Summary Emissions

Summary Detailed Test Results Sampling Procedures Location of Test Ports Diagram of Sampling

Train Particulate and Visible

Field Data Sheets Test Run 1 Test Run 2 Test Run 3 Control Room Production

Data Quality Assurance

I Quali•

Control

Procedures QA / QC Checklist Stack On-site

•asurements -Odfice Check and Temperature

Check Preliminary Traverse

w/Cyclonic

Flow -Fyrite/Orsat 8tandaNization Laboratory Analysis Equipment Calibrations Nomenclature and Test Calculations Paqe No, 1237111213141822262833343536383942ecutive Summam Entec Services,

Inc. was retained

by Belden Brick Company

to perform

particulate

and v{sual emissions

testing on Brick Plant No. 8, Tunnel Kilns 1-3 lo•ted

in Sugarcreek, Ohio, Mr. Joseph

Lotz, Mr. Eddie Rudloff

and Mr. Lalan Kirby of Entec Services,

Inc conducted the testing on August

23, 2005. Mr. John Jensen was present

from Belden Bri• and to coordinate

testing with control room activities.

Ms Lisa Duvall from.the State of Ohio Environmental

Protection

Agency

obse•ed

these tests. Particulate and visual emissions

were performed

on the Brick Plant No,8, Tunnel Kilns 1-3 which has a lime slurry spray tower and an electrostatic

precipitator

to control emissions., No difficulties

were encountered

in the field collection laboratory analysis

of the samples

by Entec Services,

of the samples

or in the

The particulate

emissions

test summary

on the following

page gives a detailed summary of each test.C)Entec Sewices,

Inc. SOURCE OVERVIEW
SOURCE PL•J•T LOCATION: SOURCE(S) NAME(S): SOURCE(S) CONDITION: SOURCE(• SHAPE: PROBE W•SH CHEMICAL: SOURCE PERMIT NUMBER; TEST PEI•FORMF..D; REFERENCE METHOD TESTS:

P•ECT MANAGER ENVIRONMENTAL ANALYST.

PROJECTLEADER

Mr. • Kirby •NVIRONMENTAL ANALYST -.ASSISTANT

M•o • Lot• ENVIRONMENTAL SFF.C•IST-

VE READERS OWNER'S REPRE•;ENTATIVE: RULING AGENCY RULING AGENCY REPRESENTATIVE: DATES T•T• CONI:CJCT!ED• ENTEC PROJECT NUMBER: EPA• EPA• EPA• EPA • EPA• 349ENTEC Services,

Inc. •,•-D Cor•rce Ave• H.• AZa•na •S02• INPUT TEST DATA

Job No:

25126 Client: Source; Belden Bdck Company Brick Plant No. 8, Kil,,n•, Field Data Run Number Symbol,

Test Date Time Test Run Began -, Ended •Time Stack Area Barometric Pressure Stack Static Pressure Pitot Tube Correction

factor .Meter Correction

Factor ,Meter Delta H @ Nozzl e D!a, meter Meter Volume Meter Tempera•:• Delta

H !mpingers Weight Gain (Moisture) Silica Gel Impinger Weight Gain (Moisture) •xygen Concentra.•on,

dr), basis, Carbon Dioxide Concen•t,!,o,,

n, dry basis Avg. Sq. Rt. of Delta,,P, Stack Temperature Total condensible

particulate

co!!ected Data Input By:

Laian Kirby

Total particulate

collected 08/23/05 1218-t323

,81 89.3 t3•817.53,5 0.824 364.9
30.9

Test Data 2 08/23/O5 13.•,15oo
21 •648 29.10 0.28

1.9• 3 0.250 44.i94 81.71.8483.18,618.03.0 0,832 367.2 28 •0 19.2

3 08/23/05 1547-1•50 6O
29.t0

AVERAGE

0.280,84
1.9•3 29:10 0.28
0.974 1.913 0,250 0.250 43.•23 43.925 82.3•77 80.17°0 82.0 t
9.8
3.0 0,815 369.9, -2.530•8 3.20.824 367.37.927,0ENTEC Services,

Inc. 16•D Comme•e Ave, bl•, Alabama •23

•, CALCU•T• TEST DATA

• Bdck P•nt •, 8 KIl• 1-3 • I•:

Run •um• 2 • 3

t.S•P•um =p•,p•

•, •

29.12

29.12

•,12

29•12 2. •t• •e P• • l&• P. •...

29.23

2&24

29•23

29.23

•, S•a• V•u• • W•r Vapr Cond• •

v• _• 4,20•

3,911 4b.S•n•V•u•ofWa•C•l•l#Siti•G• <;•

• • 0:65t •,,0.40•

0 &462 & Mois•re F•n • V •

V •_ • O.•

0:0953

0•0•25

0.0979 .•(I• •)) • •

29;•0

29:200

29,t60

•.207 10, •t •ht • S• •& • •sis

M•

• •

2&•

28.t33

2&128

2&t09 • S• Gas Ve•

=•*(•,•(TJ/(P• • 59.48

60•

58.89

5g.467 •3.• Gas F!• •a• Condi• •'(T•,F•

• • 4&• •. 4&•2

47.•i

22 VO u• • •mU• r•le

•••

v. •

73;•4 • •72;•2

71,5•

12;681

•. Palate •n•a•n.

• • •iti•S •o1•4.

• • 0.0• • 0.•=1 • 0.•.

0;0057

1.02• ,0•9

1•0i72Procedures The particulate

emission

rates were determined

using EPA Methods

1-5, CFR Title 40, Part 60, Appendix

A. The calibration

and quality assurance

procedures

of EPA CFR 40 Part 60 Appendix

A for all methods,

and the "Quality

Assurance

Handbook

for Air Pollution Measurement

System"

Votume

III Stationary

Source-Specific

Methods

were followed throughout

the duration

of the field and laboratory

testing. The most current revision

revised as of July 1, 2004, of each method

(as described

in the Federal

Register)

was used. Stac•,,Gas Volumetric

Flow The velocit•/of

the gas stream was determined

according

to EPA Reference

Method

1 and 2 by reading

the instantaneous

velocity

head with an inclined

manometer

at each sampling point with a calibrated

S-type pitot tube attached

adjacent

to the sample nozzle. The stack pressure

was measured

with the static side of an S-type pitot tube. A calibrated

pyrometer

was used to measure

stack temperature

at each sampling

point. The stack was tested for cyclonic

flow according

to EPA Reference

Method

1. Stack Gas Molecular

Weklht The carbon dioxide and oxygen concentrations

were determined

using EPA Reference Method 3 (Fyrite Method),

A sample of the flue gas was extracted

from the gas stream during each test. These samples

were analyzed

with a Fydte gas analyzer.

The molecular weight of the gas was calculated

using the moisture,

oxygen

and carbon dioxide •ntent and the measured

stack gas temperature. Moisture Content The moisture

content

used for calculating

the gas stream flow rate was determined

by measuring the amount

of condensed

moisture

in the stainless

steel condenser

and silica gel impinger

in the sampling

train as described

in EPA Reference

Method

4 at the completion of each test.The moisture

collection

system consists

of four glass impingers.

The first two impingers
were charged

with 100 ml each, the third empty, with the fourth charged

with silica gel. Ice is placed

around

the impingers

to maintain

a temperature

<68 o F. The outlet temperature of the condenser

is monitored

and recorded

throughout

the duration

of the testing to vedfy the temperature

is below <68 o F. Particulate Determination The particulate

sample train consists

of a heated stainless

steel sample probe and liner equipped with a S-type Pitot tube and thermocouple.

The probe is attached

to a sample module consisting

of a heated filter compartment

which houses

the in-line filter holder equipped with a pre-weighed

glass fiber filter for the collection

of the particulate

and impingers for determining

condensed

moisture.

The sample

module

is connected

to a control module

by means of an umbilical

cord. The control module

consist of a dry gas meter, calibrated

odfice,

leak free pump, two inclined

manometers,

temperature controllers for the heated filter compa•ment

and probe and a thermocoupte

indicator

to monitor the required

temperatures

during the testing. Particulate samples

are collected

as follows:

The sample

gas is drawn through

the sampling probe isokinetically

and passed

through

a 3-inch •atman

glass fiber filter where particulates

are removed.

The sample

gas is then passed

through

the umbilical cord to an ice-cooled

condenser

and desiccant-packed

column,

which absorbs

any remaining moisture.

The sample gas then passes through

a vacuum

pump followed

by

a dry gas meter. The dry gas meter integrates

the sample

gas flow throughout

the duration of the test. A calibrated

orifice attached

to the outlet of the dry gas meter provides real time flow rate data. A representative

particulate

sample

is acquired

by sampling

for equal periods

of time at the centroid

of a number

of equal area regions

in the exhaust

stack. The sampling

rate is adjusted

at each test point maintaining

an isokinetic

sampling

condition. After the sampling

is complete,

the filter is removed

and placed in a storage

container for shipment

back to the laboratory

for analysis.

The nozzle, probe liner and inlet side of the filter holder are quantively

washed

with a reagent

grade acetone

and stored in a marked and sealed container.

The samples

are transferred

back to the laboratory

werethey are logged in and analyzed.

The volume

of acetone

rinse is noted and transferred to a tarred fleaker and evaporated

off at 97,105 °F, This temperature

is used to prevent condensation of atmospheric

moisture

due to the cooling

effects

induced

by the evaporating acetone.

The acetone-free

sample is placed in an oven and,dried

at 105 °C for thirty minutes

and then placed in a desiccator.

After the sample has desiccated

for twenty-four hours the sample

is weighed

to the nearest

0•1 rag. The filter sample

is transferred to the original

petri dish in which the original

weight was obtained

and placed in a d•ing oven for 2 hours at 105 °C. The filter and petri dish are then placed in
a desiccator,

After the filter and petri dish have desiccated

for twenty•four

hours the sample is weighed

to the nearest

0.1 mg, Visual examination

of the samples

are made to determine

if any unusual

characteristics

of the samples

are observed.

The weight of the acetone

rinse is corrected

for the weight of the acetone

blank.Entec Servi s,

Inc 16 D Commerce

Ave. Huey•own,

AL 35023 STACK DRAWING

& TRAVERSE

POINT LOCATION C•ient: Belden BHck Company Job No. 25126 Source: Bdck Plant No, 8, Kilns 1-3 Input By: Lalan Type of Traveme: Velo¢• (V) or P•te (P):

•

Po• Tyro

•p• Po• Oi•r

4 S•ck D•ter, i•:

63 S•k A• F•: Zt,• S•k H•gh• •

1• Nu• • P•: 2
U•m D•e:

3•O

4.95

T•I N•r of T•Ve• Pol•:

•
63.0 •CHe•

312.0

l•c•s

NCHE$ Inside •ck

O•ide Nipple

2 4.2 8;2 3 7,4 11.4 5 15.8 19• 6 22.4 26.4 8 47•3 S1,3

12 61,7 65.7 AdjtmfOd points diameter > 24" no point closer than t.0 inch "Adjusted polntsd•ame•r

<_ 24" no poi•t closer than 0.S inch Stack Dlametem bet,,veen 12-24 inches minimum points am 8 4 points per port if • 812 dlametem dowrmtmam:and u•m c#.•da •s me•