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 

Commerce Avenue Hueytown, Alabama 35023 Phone: (205} 49t-6676 Fax (205) 491-6614 

www.entecserv|ces.com 
ENTEC 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•is 

Tommy Lot¢ J Tommy Lotz Jr. 

29,6B 29.?7 

4 4 

D|stffied Water Blank 

•4 

3• 

3,707A 
ENTEC Services, Inc. 

INPUT TEST DATA 

Client: 

Source: 

F•d:Oa• 

•un Number 

Test Date 

Belden Bdck Company 

ar•k plant N,o,. ,B, Kilns 1-3 

S•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 

1.81 

89.3 

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 

0.28 

0.84 

0.250 

44•194 

81.7 

83.1 

8,6 

18.0 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 9.8 

17.5 

0.824 

367.3 

21.0 
EN 

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•eom 
Entec 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 

Section 

Executive 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, 

1 

2 

3 

7 

11 

12 

13 

14 

18 

22 

26 

28 

33 

34 

35 

36 

38 

39 

42 
 ecutive 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• 

3 

4 

9 
ENTEC 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•8 

17.5 

3,5 

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 

81.7 

1.84 

83.1 

8,6 

18.0 

3.0 

0,832 

367.2 

28 •0 

19.2 

3 

08/23/05 

1547-1•50 

6O 

29.t0 

AVERAGE 

0.28 

0,84 

1.9•3 

29:10 

0.28 

0.974 

1.913 

0,250 0.250 

43.•23 43.925 

82.3 

•77 

80.1 

7°0 

82.0 

t 

9.8 

3.0 

0,815 

369.9, 

-2.5 

30•8 

3.2 

0.824 

367.3 

7.9 

27,0 
ENTEC 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•0i72 

Procedures 

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 were 
they 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•