Entec Services, Inc. 

16 D Commerce Avenue 

Hueytown, Alabama 35023 

Telephone: (205) 491-6676 

Fax: (205) 491-6614 

Results of the February 7-8, 2006 

Engineering / Compliance Testing for 

Particulate, HCL/HF and Sulfuric Acid Mist Emissions on the 

Brick Kiln Stack 

Located at the Muskogee Facility 

In Muskogee, Oklahoma 

Submitted to: 

Boral Bricks 

P.O. Box 1178 

Columbus, Georgia 31902 

Attention: Mr. Frank Porter 

Entec Project No. 36114 

Completed By: 

Project Manager 

Report Submitted: February 22, 2006 

Tom Lotz, St. 

QA/QC 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. 
Executive Summary 

Entec Services, Inc. was retained by Boral Bricks to perform Particulate, HCL/HF and 

Sulfuric Acid Mist emissions testing on the Brick Kiln Stack at the Muskogee facility 

located in Muskogee, Oklahoma. Mr. Lalan Kirby and Mr. Erik Groth of Entec Services, 

Inc. conducted the testing on February 7-8, 2006. 

No difficulties were encountered in the field collection of the samples or in the 

laboratory analysis of the samples by Entec Services, Inc. or by Stillbrook 

Environmental Testing Lab, Inc. 

The emissions test summary on the following page gives a detailed summary of each 

test run. 

1 
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0 

0 
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Deta i led Test Results 
Entec Services, Inc. 

SOURCE OVERVIEW 

SOURCE OWNER: 

PLANT LOCATION: 

SOURCE(S) NAME(S): 

SOURCE(S) CONDITION: 

SOURCE(S) SHAPE: 

PROBE WASH CHEMICAL: 

TEST PERFORMED: 

REFERENCE METHOD TESTS: 

PROJECT MANAGER 

ENVIRONMENTAL ANALYST PROJECT LEADER 

ENVIRONMENTAL ANALYST ASSISTANT 

OWNER'S REPRESENTATIVE: 

DATES TESTS CONDUCTED: 

ENTEC PROJECT NUMBER: 

Boral Brick 

Muskogee, Oklahoma 

Brick Kiln 

Engineering, Compliance Grade Testing 

Circular 

Acetone 

Particulate and HCL Testing 

Sample Location 

Volumetric Flow 

Molecular Weight 

Moisture Content 

Particulate 

Hydrogen Chloride 

EPA Method 

EPA Method 

EPA Method 

EPA Method 

EPA Method 

EPA Method 

Mr. Tommy Lotz, Jr. 

Mr. Lalan Kirby 

Mr. Edk Groth 

MroFrank Porter 

02/07/06 

36114 

1 

2 

3 

4 

5 

26A 
ENTEC Services, Inc. 

INPUT TEST DATA 

Client: Boral Brick Job No.: 36114 

Source: Brick Kiln Data Input By: Lalan Kirby 

Field Data 

Run Number 

Test Date 

Time Test Run Began Ended 

Sampling Time 

Stack Area 

Barometric Pressure 

Stack Static Pressure 

Pitot Tube Correction factor 

Meter Correction Factor 

Meter Delta H @ 

Nozzle Diameter 

Meter Volume 

Meter Temperature 

Avg. Orifice Delta H 

Impingers Weight Gain (Moisture) 

Silica Gel lmpinger Weight Gain (Moisture) 

Oxygen Concentration, dry basis 

Carbon Dioxide Concentration, dry basis 

Avg. Sq. Rt. of Delta P 

Stack Temperature 

Total Hydrogen Chloride collected, mg 

Total Hydrogen Fluoride collected, mg 

Total particulate collected 

Symbol 

0 

As 

Pbar 

Cp 

Y 

•H@ 

On 

Vrn 

AH 

Wimp 

COz 

(sqrt 

HCL 

HF 

Units 

Military Time 

02/07/06 

1129-1236 

Test Data 

02/07/06 

1316-1419 

02/07/06 

1456-1600 

minutes 60 60 60 

F• 19.635 19.635 19.635 

in. Hg 

in. H20 

in. H20 

inches 

29.90 

-0.42 

0.84 

0.971 

1.786 

0.245 

43.158 

73.4 

1.65 

52.6 

11.5 

dcf 

F 

in. Hz0 

grams 

grams 

% 18.0 

% 3.0 

0.912 

461.5 

5.82 

125.00 

113.2 

(in. H20) llz 

F 

mg 

29.90 

-0.45 

0.84 

0.971 

1.786 

0.245 

45.153 

84.8 

1.67 

58.6 

8.7 

18.0 

3.0 

0.917 

461.6 

6.08 

131.00 

101.3 

mg 

mg 

29.90 

-0.46 

0.84 

0.971 

1.786 

0.245 

45.723 

84.1 

1.71 

58.5 

10.2 

18.0 

3.0 

0.931 

470.0 

6.34 

137.00 

97.4 

AVERAGE 

60 

29.90 

-0.44 

0.84 

0.971 

1.786 

0.245 

44.678 

80.8 

1.68 

56.6 

10.1 

0.920 

464.4 

6.08 
ENTEC Services, inc. 

16-D Commerce Ave, Hue•town. Alabama 35023 

CALCULA1ED TEST DATA 

Client: Boral Brick Job No.: 36114 

Source: Brick Kiln Data Input By: Lalan Kirby 

Description Formulas Symbol Units Calculated Data 

Run Number 2 3 AVERAGE 

Time BeUlah-Ended Military Time 1129-1236 1316-1419 1456-1600 iiiiiiiiiiiiiiii!iiiiiiiiiiiiiiiiiii!iiiil 

1. Stack Pressure P• Pg 13,6 Ps in. Hg 29.87 29.87 29.87 29.87 

2, Meter Pressure P•r &H 13.6 Pm in. Hg 30.02 30,02 30.03 30.02 

3. Standard Meter Volume 17.64"Y* (vc,/'rm)* (P• ,•H 13.6) Vm(•) dscf 41.608 42.621 43.219 42.483 

4a. Standard Volume of Water Vapor Condensed =0.04706"W•.•, v•=• scf 2,475 2.758 2,753 2.662 

4b. Standard Volume of Water Collected in Silica Gel =0.0471•'W• v.,•,,• scf 0.542 0.410 0.481 0.478 

5. Moisture Fraction =(V•l=• Vws•l(Std))/(Vwc•std) Vw•std Vm{stdl B• fraction 0.0676 0.0692 0.0696 0.0688 

9, Molecular Weight Of Stack Gas, dW basis 0.32"(0•)+ 0.44"(c02)+0.28"(100-(02)-(c0=)) Md g/g-mole 29.200 29.200 29.200 29.200 

10. Molecular Weight Of Stack Gas, wet basis M•*(1-Bws)+18.0*(l•) I• g/g--mole 28,443 28.425 28,420 28.429 

11. Average Stack Gas Velocity 85.49"C.*(sqrt ,•P).vg*SQRT((T.) (P.*Mw)] v. rids 68.19 68.62 69.99 68.932 

12, Stack Gas Flow @ Stack Conditions 60*vs*A• Q• acfra 80,332 80,838 82,455 81,208 

13. Stack Gas Flow @ Standard Conditions Q.*(T,=EI",)*(P•/P,•,] Q. scfra 45,930 46,211 46,712 46,284 

!14. Stack Gas Flow @ Dry Standard Conditions Q.*(1-B.=)*(T=ET.)*(PJP=a] Q• dscfm 42,824 43,014 43,460 43,100 

14b, Hydrogen Chloride concentration @ Std.Cond.,Grains/Cu.Ft. =(0.01543*HCLr•)IQst= HCLcs grldscf 0,002 0,002 0.002 0.002 

14b. Hydrogen Fluoride concentration @ Std,Cond.,Grains/Cu,Ft. =(O.01543*HFrr•j)lQ.¢d HFcs gr/dscf 0.046 0.047 0.049 0.048 

15. Particulate concentration @ Standard Conditions =0.01543*rnr•V•{=td) cs gr/dscf 0.0420 0,0367 0.0348 0,0378 

15b. Hydrogen Chloride emissions, Ibs per hour =(60R'000)*HCLQ=•*Q=• HCl -Ibs/hr Ibslhr 0.79 0.81 0.84 0.82 

15b. Hydrogen Fluoride emissions, Ibs per hour =(60/7000)*HFQ•t•*Qst= HF -Ibs/h¢ Ib$1hr 17.02 17.49 18.22 17 57 

21. Particulate emissions {60/7000)*¢s*Q=• PMR Ibll•r 15,41 13.52 12,96 13.97 

22. Volume collected through nozzle =TJP,*[0.002669*V•=+ Vr,*Y*Po•I"m] V. acf 78.052 80.100 81.999 80.050 

23. Particulate concentration, @ actual conditions =0.01543"rn#V. c. grlacf 0.0224 0.0195 0.0183 0,0201 

24. Isokinetic Sampling Rate, Percent t00*Vnl (60*v=*A.'6) 0/o 97.12 99.05 99.41 98.52 

Post Meter Orifice Cal. (EMC ALT-009 Yqa) yD. iiiiiiiiii;i!i;;!i;ili;il;i!iiiiiii;i;;l 1.0033 0.9737 0.9723 0.9831 

% Difference, (Calibration must be within 5% of original Y-factor) ::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: ol 24% 
Entec Services, Inc. 

SOURCE OVERVIEW 

SOURCE OWNER: 

PLANT LOCATION: 

SOURCE(S) NAME(S): 

SOURCE(S) CONDITION: 

SOURCE(S) SHAPE: 

PROBE WASH CHEMICAL: 

TEST PERFORMED: 

REFERENCE METHOD TESTS: 

PROJECT MANAGER 

ENVIRONMENTAL ANALYST PROJECT LEADER 

ENVIRONMENTAL ANALYST ASSISTANT 

OWNER'S REPRESENTATIVE: 

DATES TESTS CONDUCTED: 

ENTEC PROJECT NUMBER: 

Boral Brick 

Muskogee, Oklahoma 

Brick Kiln 

Engineering, Compliance Grade Testing 

Circular 

IPA and Water 

Sulfuric Acid Mist 

Sample Location 

Volumetric Flow 

Molecular Weight 

Moisture Content 

Sulfudc Acid Mist 

EPA Method 

EPA Method 

EPA Method 

EPA Method 

EPA Method 

Mr. Tommy Lotz, Jr. 

Mr. Lalan Kirby 

Mr. Edk Groth 

Mr.Frank Porter 

02•8•6 

36114 

1 

2 

3 

4 

8 
ENTEC Services, Inc. 

16-D Commerce Ave Hues/town A abama 35023 

INPUT TEST DATA 

Client: Boral Brick Job No.: 38114 

Source: Brick Kiln Data Input By: i•l=n Kirby 

Field Data 

Run Number 

Test Date 

Time Test Run Began Ended 

Sampling Time 

Stack Area 

Barometric Pressure 

Stack Static Pressure 

Pitot Tube Correction factor 

Meter Correction Factor 

Meter Delta H @ 

Iozzle Diameter 

Meter Volume 

Meter Temperature 

Avg. Orifice Delta H 

Impingers Weight Gain (Moisture) 

Silica Gel Impinger Weight Gain (Moisture) 

Oxygen Concentration, dry basis 

Carbon Dioxide Concentration, dry basis 

Avg. Sq. Rt. of Delta P 

Stack Temperature 

Symbol Units Test Data 

1 2 

02/08/06 02/08/06 

Military Time 0832-0935 

minutes 60 

A= FtZ 19.635 

Pbar 

Cp 

Y 

Dn 

Vrn 

Wimp 

Ws,• 

O2 

C02 

in. Hg 29.70 

in. H20 -0.56 

in. H20 

inches 

dcf 

F 

in. Hz0 

grams 

grams 

% 

(sqrt/tP)av. 

0.84 

1028-1130 

60 

19.635 

29.70 

-0.52 

0.84 

0.971 0.971 

1.786 1.786 

0.245 

46.149 

80.6 

1.75 

23.5 

18.0 

2.0 

0.938 

481.7 

0.245 

45.429 

83.3 

1.72 

25.9 

28.0 

18.5 

1.5 

0.931 

484.7 

3 

02/08/06 

1221-1323 

6O 

19.635 

29.70 

-0.52 

0.84 

AVERAGE 

60 

29.70 

-0.53 

0.84 

0.971 0.971 

1.786 1.786 

0.245 0.245 

45.43O 45.669 

81.5 81.8 

1.70 

24.0 

28.5 

1.72 

24.5 

28.6 

17.5 18.0 

2.0 1.8 

0.929 

477.5 

0.932 

481.3 
ENTEC Services, Inc. 

Client: Boral Brick Job No.: 36114 

Source: Brick Kiln Data Input By: Lalan Kirby 

Description Formulas Symbol Units Calculated Data 

2 3 Run Number 

Test Date 

Time Began-Ended Military Time 

1. Stack Pressure Pbar Pal 13.6 P= irL Hg 29.66 

12. Meter Pressure Pbzr AH 13.6 Pm in. Hg 29.83 

3. Standard Meter Volume 17.64" Y* (V,•T,,)* (Pbar &H 13.6 Vm{=,•) dscf 43.616 

4a. Standard Volume of Water Vapor Condensed =0.04706*W•rnp V, $cf 

4b. Standard Volume of Water Collected in Silica Gel =0.0471s*W,• vw,•,,• scf 

5. Moisture Fraction =(v•,,(,td• Vwsq(Stdi)/(Vw¢(•d) Vwsq{sto) Vmistd) •s fraction 0.0539 

9. Molecular Weight Of Stack Gas, dry basis 0.32"(O2)+ o.,•4*(coz)+o.28*(lOO-(Oz)-(co•) Md g/gomole 29.040 

10. Molecular Weight Of Stack Gas, wet basis •*(I-Bw,)+IS.0*(B,,} M, gig-mole 

02108/06 02/08/06 02/08/06 

0832-0935 1028-1130 1221-1323 

AVERAGE 

29.66 29.66 29.66 

29.83 29.82 29.83 

42.716 42.859 43.064 

1.129 1.151 

1.344 1.347 

1.106 1.219 

1.377 1.320 

0.0561 0.0546 0.0548 

28.980 29.020 29.013 

28.445 28.364 28.419 28.409 

11. Average Stack Gas Velocity 85.49*Cp*(sqrt &P)av,•*SQRT((Ts) (P•*M,,)) v, Pals 71.16 70.81 70.36 70.775 

12. Stack Gas Flow @ Stack Conditions 60*vs*A• Q= acfm 83,832 83,422 82,887 83,380 

13. Stack Gas Flow @ Standard Conditions Q•*(Tst•JTs)*(PJPsCd) Qs scfm 46,574 46,206 46,260 46,347 

%. Stack Gas Flow @ Dry Standard Conditions Qa*(loBws)*(Tsta/Ts)*(Ps/P•td) Q•=e dscfm 44,066 43,614 43,737 43,805 

16. Sulfur Dioxide (SO2) Gas Concentration From Titrations C,o• Ibs/dscf 2.04E-05 2.70E-05 2.82E-05 2.52E-05 

16. Sulfuric Acid Mist (H2SO4) Gas Concentration From l"itrations C.•so Ibs/dscf 5.64E-06 6.11E-06 7.83E-06 6.53E-06 

21. Sulfur Dioxide (SO2) Gas Concentration From TitraUons SO•-Ib/hr Ib/hr 53.97 70.73 73.89 66.20 

21. Sulfuric Acid Mist (H2SO4) Gas Concentration From Titrations HzSO4-1b/hr Ib/hr 14.91 15.98 20.55 17.15 

22. Volume collected through nozzle =T,/P,*[0.002669*V•c+ Vm*Y*P,n/Tm] V. acf 82.974 81.702 81.220 81.966 

24. Isokinetic Sampling Rate, Percent lO0*Vn/(60*v,*An*9)= % 98.94 97.90 97.95 98.26 

Post Meter Orifice Cal. (EMC AL'r-009 Yqa) y ;iiiiiii•iiiiiiiiiiiiiiiiiiiiiiiii! 0 9774 0 9890 0 9789 0 9818 

% Dfference :•:•:i:i:i:!:i:!:i'"'.'.'.'.'. (Ca brat must be th 5% of g Y+factor) ::::::::iil •ii•iii;ii!•;;;;;•!•i!;i;i;i;;•:i•i;i;iii!i;iii::::iiiiii:::: ::iii 1•°/, 
Location of Test Ports 
Entec Services, inc 

16 D Commerce Ave. Hue}t,.town AL 35023 

STACK DRAWING & TRAVERSE POINT LOCATION 

Client: Boral Brick Job No. 36114 

Source: Brick Kiln Input By: Lalan Kirby 

Type of Traverse: Velocity (V) or Particulate (P): P 

Stack Diamet•)r, inches: • 

Stack Height, feet: 4• 

Stack Properties: Inches Duct Diameters 

Upstream Disturbance: 

Downstream Disturbance: 144.@ 

3.20 

2.40 

Port Type Nipple 

Stack Area, Ft•: 

Number of Ports: 

Length of Port, inches: 

Total Number of Traverse Points: 

Number of Points per diameter: 

Port Diameter 

19.635 

2 

24 

12 

60.0 

192.( NCHES 

t44.0 •C.ES 

Point No. 

Inside Stack Outside Nipple 

Inches Inches 

1.3 6.3 

2 4.0 9.0 

3 7.1 12.1 

4 10.6 15.6 

5 15.0 20.0 

6 21.4 26.4 

7 38.6 43.6 

8 45.0 50,0 

9 49.4 54.4 

10 52.9 57.9 

11 56.0 61.0 

12 58.7 63.7 

Adjusted poinls diameter > 24" no point closer than 1.0 inch 

Adjusted points diameter _< 24" no point closer than 0.6 inch 

Stack Diameters between 12-24 inches minimum points are 8 

4 points per port if the 812 diameters downstream and 

upstream criteria is met, 

12