Cornpliance Stack E nission 

Test Report 

Determination of Total Filterable Particulate 

Matter, Hydrogen Chloride, Hydrogen 

Fluoride and Visible Emissions 

Kiln No. 2 

EPA Methods 1, 2, 3, 4, 5, 9 and 26A 

Glen-Gery Coruoration - York Facility 

York, Pennsylvania 

Date Conducted: October 9, 2007 

Job Number: 070918 

Prepared by: 

:Z:77mi ~~ 

ing, Inc. 

PO Box 41156 

Cleveland OH 44141-0156 

Phone: (800) EPA-AIR7 (372-2471) 

Report Date: November 7, 2007 
SuperiorQuality Air Compliance 

Emission Testing. 

Valid Results 

Guaranteed. Testing, Inc. 

P.O. Box 41156 Cleveland, Ohio 44141 

1-800-EPA-AIR1 www.aircomp.com 

testing@aircomp.com 

November 7, 2007 

Jerry Carrier 

Director of Research/Development 

Glen-Gery Corporation - York Facility 

433 South Pottsville Pike 

Shoemakersville, Pemisylvania 19555 

Dear Jerry: 

The following report provides the results of the compliance emission testing conducted on 

October 9, 2007. These results are a product of the application of the U.S. EPA Stationary 

Soarce Sampling Methods listed in 40 CFR Part 60 Appendix A that were in effect at the time 

of this test. 

Please mail one copy of this report along with any other supportive process operating data 

collected during this test to your local EPA representative. You should also attach a cover 

letter (on company letterliead) stating the purpose and the outcome of this test. Additionally, 

you may address, preferably in a timetable format, any obligations or implications that might 

be necessary to achieve environmental compliance because of the result of this test. 

Please do not hesitate to call if you have any questions or concerns about these test results. 

On behalf of Air Compliance Testing, I would also like to personally thank you for the 

opportunity to work with you on this testing project and would enjoy the opportunity to work 

with you again on any additional future testing projects. 

Sincerely, 

v 

Phaneendra 

G 

 Uppalapati 

Air Quali Engineer 

0 y~ 

Robert J. Lisy, . 

Quality Assurance Officer 
Compliance Stack Emission Test Report Glen-Gerv Corporation - York Facilitv 

Table of Contents 

Page 

1.0 INTRODUCTION 2 

l.l Summary of Test Program 2 

1.2 Key Personnel 2 

2.0 SUMMARY AND DISCUSSION OF TEST RESULTS 3 

2.1 Objectives and Test Matrix 3 

2.2 Field Test Changes and Problems 3 

23 Presentation of Results 4 

3.0 PLANT AND SAMPLING LOCATION DESCRIPTIONS 7 

3.1 Process Description and Operation 7 

3.2 Control Equipment Description 7 

3.3 Flue Gas Sampling Locations 7 

3.4 Process Sampling Location 8 

4.0 SAMPLING AND ANALYTICAL PROCEDURES 12 

4.1 Test Methods 12 

4.2 Procedures for Obtaining Process Data 13 

5.0 INTERNAL QA/QC ACTIVITIES I S 

5.1 QA Audits IS 

5.2 QA/QC Problems 15 

6.0 APPENDIX 19 

Test Date: October 9, 2007 Page 1 Air Compliance Testing, Inc. - 070918 
Compliance Stack Emission Test Report Glen-Gerv Corporation - York Facilitv 

1.0 INTRODUCTION 

1.1 Summary of Test Program 

Glen-Gery Corporation - York Facility, located in York, Pennsylvania contracted Air Compliance Testing, 

Ine. of Cleveland, Ohio to conduct compliance stack emission testing for their Kiln No. 2. Testing was 

performed to satisfy the emission testing requirements pursuant to Operating Permit No. 67-05045B. The 

testing was performed on October 9, 2007. 

Simultaneous sampling was perforined at the Kiln No. 2 Dry Limestone Adsorber (DLA) Inlet Duct and at 

the ICiln No. 2 DLA Exhaust Stack to determine the mass emission rate of hydrochloric acid (HCI) and 

hydrofluoric acid (HF). Sampling was also performed at the Kiln No. 2 DLA Exhaust Stack to deterinine 

the mass emission rate oftotal filterable particulate inatter (PM). Visible Emissions (VEs), measured as 

percent opacity were also determined at the Kiln No. 2 DLA Exriaust Stack. Testing was conducted while 

operating at maximum production level for the products listed in the appendix. During this test emissions 

from Kiln No. 2 were controlled by the DLA. 

The test methods that were conducted during this test were EPA Methods I, 2, 3, 4, 5, 9, and 26A. 

1.2 Key Personnel 

The key personnel who coordinated this test program (and their phone numbers) were: 

Jerry Carrier, Director of Research/Development, Glen-Gery Corporation, 610-374-4011 

Rick Millard, Pennsylvania Dept of Environmental Proteetion, 717-783-2300 

Philip J. Billick, President, Air Compliance Testing, Inc. 800-372-2471 

S'rn Hoi Chiew, Project Manager, Air Compliance Testing, Inc. 800-372-2471 

Test Date: October 9, 2007 Page 2 Air Compliance Testing, Inc. - 070918 
Compliance Stack Emission Test Repo t Glen-Gerv Corporation - York Facilitv 

2.0 SUMMARY AND DISCUSSION OF TEST RESULTS 

2.1 Objectives and Test Matrix 

The purpose of this test was to determine the mass emission rate of HCl and HF at the Kiln No. 2 DLA Inlet 

Duct and at the Kiln No. 2 DLA Exhaust Stack and also to detennine the mass emission rate of total filterable 

PM at the Kiln No. 2 DLA Exhaust Stack while operating at maximum production levels for the products 

listed in the appendix at a predetennined limestone extraction setting. The purpose of this test was also to 

determine VEs (as %-opacity) at the Kiln No. 2 DLA Exhaust Stack while operating at maximum production 

levels for the products listed in the appendix at a predetermined limestone extraction setting. Testing was 

performed to prove compliance with the Plan Approval Requirements of Operating Permit No. 67-05045B. 

The specific test objectives for this test were to: 

Measure the concentration of I-ICl and HF at the Kiln No. 2 DLA Inlet Duct and at the Kiln No. 2 DLA 

Exhaust Stack and also measure the concentration of total filterable PM at the Kiln No. 2 DLA Exhaust 

Stack while operating at maximum production levels for the products listed in the appendix at a 

predetermined limestone extraction setting. 

Measure the dry standard and actual volumetric flow rate of the stack gas at the Kiln No. 2 DLA Inlet Duct 

and at the Kiln No. 2 DLA Exhaust Stack while operating at maximum production levels for the products 

listed in the appendix at a predetermined limestone extraction setting. 

Utilize the above variables to determine the mass emission rate of HCl and HF at the Kiln No. 2 DLA Inlet 

Duct and at the Kiln No. 2 DLA Exhaust Stack and also determine the mass emission rate of total filterable 

PM at the Kiln No. 2 DLA Exhaust Stack while operating at maximum production levels for the products 

listed in the appendix at a predetermined limestone extraction setting. 

Deterinine VEs (as %-opacity) Kiln No. 2 DLA Exhaust Stack while operating at maximum production 

levels for the products listed in the appendix at a predetermined limestone extraction setting. 

Table 2.1 presents the sampling and analytical matrix log for this test. 

2.2 Field Test Changes and Problems 

No 6eld test changes or problems occurred during the performance of this test that would bias the accuracy of 

the results of this test. 

Test Date: October 9, 2007 Page 3 Air Compliance Testing, Inc. - 070918 
Compliance Stack Emission Test Report Glen-Gerv Corporation - York Facilitv 

2.3 Presentation of Results 

A single sampling train was utilized during each run at each location to determine the mass emission rate of 

HCI and HF at the Kiln No. 2 DLA Inlet Duct and at the Kiln No. 2 DLA Exhaust Stack and also determine 

the mass emission rate of total filterable PM at the Kiln No. 2 DLA Exhaust Stack while operating at 

maximum production level for the products listed in the appendix at a predetermined limestone extraction 

setfing. A single sampling train at the Kiln No. 2 DLA Inlet Duct measured the stack gas volumetric flow rate, 

dry molecular weight, moisture content, and eoncentrations of HCI and HF. A single sampling train at the 

ICiln No. 2 DLA Exhaust Stack measured the stack gas volumetric flow rate, dry molecular weight, moisture 

content, and concentrations of total filterable PM, HCI, and HF. 

Table 2.2 displays the mass einission rate of HCI and HF measured at the Kiln No. 2 DLA Inlet Duct and at 

the Kiln No. 2 DLA Exhaust Stack and also displays the mass emission rate of total filterable PM measured 

at the Kiln No, 2 DLA Exhaust Stack while operating at maximum production levels for the products listed 

in the appendix at a predetermined limestone extraction setting. 

Table 2.2 also displays the maximum 6-minute average of opacity measured at the Kiln No. 2 DLA Exhaust 

Stack while operating at a maximum production level for the products listed in the appendix at a 

predetermined limestone extraction setting. 

Test Date: October 9, 2007 Page 4 Air Compliance Testing, Inc. - 070918 
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Compliance Stack Emission Test Repo t Glen-Gerv Corporation - York Facility 

3.0 PLANT AND 8AMPLING LOCATION DESCRIPTIONS 

34 Process Description and Operation 

Glen-Gery Corporation - York facility operates two natural gas-fired tunnel kilns. The kilns produce brick of 

various sizes and colors. Kiln 2(Unit ID 102) has been fitted with a dry limestone absorber (DLA) system 

manufactured by Hellmich to control Hydrogen Fluoride and Hydrogen Chloride emissions. 

The Kiln No. 2 was in operation during the performance of this test event. 

Figure 3.1 depicts the process schematic. 

3.2 Control Equipment Description 

The DLA system is comprised of a liinestone cascade absorber equipped with a limestone silo located atop the 

DLA Exhaust gases froin the kihi pass through the absorber. The absorber is equipped with a peeling drum 

that mechanically removes the reacted layer from the crushed lunestone. The "peeled" limestone is 

pneuinatically conveyed from the peeling drum back to the limestone feed bin, located on top of the absorber. 

The reacted layer that has been peeled from the limestone is discharged via gravity to a hopper for disposal. 

During this test emissions from the Kiln No. 2 were controlled by the DLA and the bypass damper was closed. 

3.3 Flue Gas Sampling Locations 

3.3.1 - Kiln No. 2 DLA Inlet Duct 

The Kiln No. 2 DLA Inlet Duct was elliptical in shape with measured inner diameters of 47.5-inches and 47.7- 

inches. The stack was oriented in the horizontal plane and was accessed from a perinanent platform. Two (2) 

4.0-inch I.D. sampling ports were located 90 0apart from one another at a location that met EPA Method 1, 

Section 1 1.1.1 criteria. On July 23, 2007, the stack was traversed to verify the absence of cyclonic flow. An 

average yaw angle of 6.83° was measured. Therefore, the sampling location also met EPA Method 1, Section 

11.4.2 criteria. During emissions sampling, the stack was traversed for stack gas volumetric flow rate, dry 

molecular weight, moisture content, HCI, and HF concentration determination. 

Test Date: October 9, 2007 Page 7 Air Compliance Testing, lnc. - 070918 
Compliance Stack Emission Test Report Glen-Gerv Corporation - York Facility 

33.2 - Kiln No. 2 DLA Exhaust Stack 

The Kiln No. 2 DLA Exhaust Stack was elliptical in shape with measured inner diameters of 47.5-inches and 

47.0-inches. The stack was oriented in the vertical plane and was accessed from a permanent platform. Two 

(2) 4.0-inch I.D. sampling ports were located 90° apart from one another at a location that met EPA Method 1, 

Section 1 l.l .l criteria. On July 23, 2007, the stack was traversed to verify the absence of cyclonic flow. An 

average yaw angle of 3.42° was measured. Therefore, the sampling location also met EPA Method 1, Section 

11.4.2 criteria. During emissions sampling, the stack was traversed for stack gas volumetric flow rate, dry 

molecular weight, moisture content, total filterable PM, HCI, and FTF concentration determination. 

Figures 3.2 and 3.3 schematically illustrate the traverse point and sample port locations utilized. 

3.4 Process Sampling Location 

Proeess sampling was completed by Glen-Gery as part of their QA/QC program and included raw material 

sampling at the pug mill as well as Fire Check Key testing in the kiln. In addition, '/z brick was removed from 

cars after the drier/prior to kiln entry as well as at kiln exit for purposes of mass balance testing if results of 

the stack test did not indicate compliance. Results from the QA/QC testing were unavailable at the time of 

this report. 

Test Date: October 9, 2007 Page 8 Air Compliance Testing, Inc. - 070918 
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Compliance Stack Emission Test Report Glen-Gerv Corporation - York Facilitv 

C~ 

120.0" 

2.53 Equivalent Diameters 

Upstream from 

Disturbance 

(2) 4.0" I.D. 

~ Sampling Ports 

located 90°Apart 

660.0" 

13.89 Equivalent 

Diameters Downstream 

from Disturbance 

V x 47.0" I. D. 

Elliptical Stack 

Port 2 

Distance From Distance From 

Point % of Duct Depth Inside Wall (in.) Inside Wall (in.) 

Port 1 Pnrt 2 

1 4.4 2.1 2.1 

2 14.6 6.9 6.9 

3 29.6 14.1 1319 

4 70.4 33.4 33.1 

5 85.4 40.6 40.1 

6 95.6 45.4 44.9 

Figure 3.3 - Kiln No. 2 DLA Lxhaust Stack Traverse Point Location Drawing 

Test Date: October 9, 2007 Page 11 Air Compliance Testing, Inc. - 070918 
Compliance Stack Emission Test Report Gien-Gerv Corporation - York Facility 

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4.1 Test Methods 

4.1.1 EPA Method 1: Sample and Velocity Traverses for Stationary Source 

Principle: To aid in the representative measurernent of pollutant emiesions and/or total volumetric flow rate 

from a stationary source, a measurement site where the effluent stream is flowing in a known direction is 

selected, and the cross-section of the stack is divided into a number of equal areas. A traverse point is then 

located within each of these equal areas. This method was utilized in its entirety as per the procedures 

outlined in 40 CFR Part 60, Appendix A. 

4.1.2 EPA Method 2: Deterinination of Stack Gas Velocity and Volumetric Flow Rate (Type S) 

Principle: The average gas velocity in a stack is determined from the gas density and from measurement of 

the average velocity head with a Type S(Stausscheibe or reverse type) pitot tabe. This method was utilized in 

its entirety as per the procedures outlined in 40 CFR Part 60, Appendix A. 

4.1.3 EPA Method 3: Gas Analysis for the Determination of Dry Molecular Weiglit 

Principle: A gas sample is extracted from a stack by one of the following methods: (1) single-point, grab 

sampling; (2) single-point, integrated sampling; or (3) multi-point, integrated sampling. The gas sample is 

analyzed for percent CO2, percent 0 2, and if necessary, for percent CO. For dry molecular weight 

determination a Fyrite analyzer will be used for the analysis. This method was utilized in its entirety as per 

the procedures outlined in 40 CFR Part 60, Appendix A. 

4.1.4 EPA Method 4: Determination of Moisture Content in Stack Gases 

Principle: A gas sample is extracted at a constant rate from the source; moisture is removed from the sample 

stream and determined either volumetrically or gravimetrically. This method was utilized in its entirety as per 

the procedures outlined in 40 CFR Part 60, Appendix A. 

4.1.5 EPA Method 5: Determination of Particulate Emissions from Stationary Sources (Front-Half PM only) 

Principle: Particulate matter (PM) is withdrawn isokinetically from the source and collected on a glass fiber 

filter maintained at a temperature in the range of 120 ± 14°C (248 t 25°F) or such other temperature as 

speeified by an applicable subpart of the standards or approved by the Administrator, U.S. Environmental 

Protection Agency, for a particular application. The PM mass, which includes any material that condenses at 

or above the filtration temperature, is determined gravimetrically after removal of uncombined water. This 

method was utilized in its entirety as per the procedures outlined in 40 CFR Part 60, Appendix A. 

4.1.6 EPA Method 9: Visual Determination of the Opacity of Emissions from Stationary Sources 

Principle: The opacity of emissions from stationary sources is deterinined visually by a qualified observer. 

This method was utilized in its entirety as per the procedures outlined in 40 CFR Part 60, Appendix A. 

Test Date: October 9, 2007 Page 12 Air Compliance Testing, Inc. - 070918 
Compliance Stack Emission Test Report Glen-Gerv Corporation - York Facilitv 

4.1.7 EPA Method 26A: Deterinination of Hydrogen Halide and Halogen Emissions from Stationary SourcesIsokinetic Method 

Principle: This method is applicable for determining emissions of hydrogen halides (HX) [hydrogen chloride 

(HCl), hydrogen bromide (HBr), and hydrogen fluoride (HF)] and halogens (X Z) [chlorine (C12) and bromine 

(BrZ)] from stationary sources. This method collects the emission sample isokinetically and is therefore 

particularly suited for sampling at sources, such as those controlled by wet scrubbers, emitting acid particulate 

matter (e.g., hydrogen halides dissolved in water droplets). This method was utilized in its entirety as per the 

procedures outlined in 40 CFR Part 60, Appendix A. 

The sampling train utilized during this testing project is depicted in Figure 4.1. 

4,2 Procedures for Obtaining Process Data 

Process data was recorded by Glen-Gery Corporation - York Facility personnel utilizing their typical record 

keeping procedures. Recorded process data was provided to Air Compliance Testing, Ine, personnel at the 

conclusion of this test event. The process data is located in the Appendix and includes the following. 

Glen-Gery personnel recorded the following process data during the performance test: 

Kiln Throughput (Tons fired brick/hour) 

Type of Brick in Kiln during testing 

Bypass Damper Position 

Limestone extraction setting 

Source and Grade of Limestone 

Test Date: October 9, 2007 Page 13 Air Compliance Testing, lne. - 070918 
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Compliance Stack Emission Test Report Gien-Gerv Corporation - York Facilitv 

5.0 INTERNAL QA/QC ACTIVITIES 

5.1 QA Audits 

Tables 5.1 - 5.3 illustrate the QA audit activities that were performed during this test. 

All meter boxes and sampling trains used during sainpling performed within the requirements of their 

respective methods as is shown in Tables 5.1 and 5.2. Al) pre-test and post-test leak checks were well below 

the applicable limit. Minimum metered volumes and percent isokinetics were also inet where applicable. 

Table 5.3 displays the results of the EPA Metliod 26A Audit Sample analysis. The results were transmitted by 

e-mail to Mr. Rick Millard, Pennsylvania Dept of Environmental Protection. On October 30, 2007, Mr. 

Millard informed Air Compliance Testing, Inc. that the two (2) reported audit concentrations met EPA Method 

26A, Section t 1.5.3 criteria. 

S}hawn Bodnar was certified on October 3, 2007 as a Visible Emissions Evaluator. The certification expires in 

six months from the issue date. 

Por quality assurance, the observer obtained a view of the einissions with the best available contrasting 

background and w'rth the sun oriented in the 140° sector to his back. Readings were taken every 15 seconds 

and made to the nearest 5% opacity. 

5.2 QA/QC ProBlems 

No QA/QC problems occurred during this test event. 

Test Date: October 9, 2007 Page 15 Air Compliance Testing, Inc. - 070918 
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Compliance Stack Emission Test Report Glen-Gerv Corporation - York Facilitv 

. t; _•94,1 G7/1 

Appendix attached. 

Test Date: October 9, 2007 Page 19 Air Compliance Testing, Inc. - 070918 
U •• 4, ,M 

to 

Compliance Stack Emission Test Report 

Determination of Total Falterable Particulate 

Matter, Hydrogen Chloride, Hydrogen 

Fluoride and Visible Emissions 

Kiln No. 2 

EPA Methods 1, 2, 3, 4, 5, 9 and 26A 

Glen-Gerv Corporation - York Facility 

York, Pennsylvania 

Date Conducted: October 9, 2007 

Job Number: 070918 

Prepared by: 

Air Compliance Testing, Inc. 

PO Box 41156 

Cleveland OH 44141-0156 

Phone: (800) EPA-AIR1 (372-2471) 

Report Date: November 7, 2007 
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