Final Test Report 

for

BSCP - Kiln Emission Test #2415

Based on information and belief formed I have reviewed all testing details and 

after reasonable inquiry, I certify that results in this test report and hereby 

the statements and information in this certify that the test report is authentic 

test report are true, accurate, and and accurate.

complete.

/ /

Permitted Facility Representative / Testing Company Representative / 

Name: Bradley Belden Name James E. Phillippi

Title: Corporate Manager - Occupational & Title: Senior Project Manager

Company: Belden Brick Company Company: Blue Mountain Environmental 

Sign 6/24/2011 Sign Date: 6/15/2011

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BSCP - Kiln Emission Test #2415

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Facility Testing Company:

The Belden Brick Company - Plant 2 Blue Mountain Environmental Management 

375 Dover Rd NW 1191 Pittsburgh Road

Sugarcreek OH 44681 Valencia PA 16059

Contact Bradley Belden Contact James Phillippi

Phone: 330-456-0031 Phone: 724-898-4500

Fax: 330-456-2694 Fax: 724-898-2908

Email: bradley.belden@beldenbrick.com Email: jphillippi@bluemountainusa.com

Industry/SCC/NAIS: 327121 AFS #: FRS #:

Air Permit Number: Permitted Source 

06-79-00-0118 P201 Kiln Outlet

Permitted Maximum Process Max. Normal Operation Process Target Process Test Rate

10.65 tons/hr per kiln 5.19 tons/hr 5.19 tons/hr

SCC / Description:30500311 Industrial Processes - Mineral Products - Brick Manufacture - Curing and Firing:

Gas-fired Tunnel Kilns 

The following state and federal regulations that apply to the proposed testing:

Regulation Description Compound Limit Unit

Section 114 of the Clean Air Act 0

Description of the source (including control equipment). Please see the attachments for source

or

Belden Brick Plant 2 produces construction grade bricks. Plant 2 has one Kiln. The process begins when a 

clay/shale material is mined form the ground and processed through a primary crusher. This crushed raw 

material is transferred via conveyor to a storage building. The material is processed through a secondary 

crusher followed by particle sizing with a series of screens. The properly sized material is stored in a silo until it 

is metered into the plant. Once in the plant, the processed material is extruded into the shape of a brick and 

loaded onto a kiln car. The kiln car is moved first into a dryer, then into the natural gas fired kiln, where it is 

fired with natural gas at various temperatures depending on the desired product and the structure of the unit. 

After firing is completed, the brick is cooled to approximately 300 degrees Fahrenheit before being unloaded via 

Sampling Location Information:

Round

Duct Rect. Duct Equiv. Distance from Distance from Number of Min.Travers 

Location Diam. Length /Width Diam upstream dist. downstream dist. Traverse Ports Points

Outlet of 56 0 0 0 201.6 160.8 2 24

Control 

Test Parameter Information:

Target Test Number of Test Run Sample 

Location Parameter Method Duration Points Comments

Outlet of Hydrogen Chloride Method 26A 3 60 0

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BSCP - Kiln Emission Test #2415

6/24/2011

 process flow diagram: an automatic unloading system.

Outlet of Hydrogen Fluoride Method 26A 3 60 0

Control 

Outlet of Hydrogen Chloride Method 26A 0

Control 

Outlet of Chlorine Method 26A 3 60 0

Control 

Outlet of Filterable Particulate Method 29 3 60 0

Control 

Outlet of Selenium Method 29 3 60 0

Control 

Outlet of Nickel Method 29 3 60 0

Control 

Outlet of Mercury Method 29 3 60 0

Control 

Outlet of Manganese Method 29 3 60 0

Control 

Outlet of Antimony Method 29 3 60 0

Control 

Outlet of Arsenic Method 29 3 60 0

Control 

Outlet of Cobalt Method 29 3 60 0

Control 

Outlet of Chromium Method 29 3 60 0

Control 

Outlet of Beryllium Method 29 3 60 0

Control 

Outlet of Cadmium Method 29 3 60 0

Control 

Outlet of Lead Method 29 3 60 0

Control 

The following describes any modifications and/or deviations to the applicable test 

methods. If alternative methods were requested, see the attachments for 

documentation of request AND approval, including dates.

None

Page 3 of 11
BSCP - Kiln Emission Test #2415

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Sampling / Stack Data Results 

Location Outlet of Control Device - Method 26A

Average

Run Number 1 2 3

Test Date 3/31/2011 3/31/2011 3/31/2011

Run Start Time 11:40:00 12:50:00 PM 2:00:00 PM

Run Finish Time 12:40:30 PM 1:50:30 3:00:30 PM

Net Run Time, minutes 60 60 60

Dry Gas Meter Volume Sampled, dscf 39.899 38.879 39.391 39.390

Moisture Content of Stack Gas, % 3.88 4.85 5.31 4.680

Moisture Saturation at Stack Gas Temperature, % 100.00 100.00 100.00 100.000

Carbon Dioxide, % 6.9 3 3 4.300

Oxygen, % 16.2 15.9 15.9 16.000

Average Stack Gas Temperature, °F 312.63 312.33 312.88 312.613

Dry Volumetric Flow Rate, dry scfm 13,736.7 13,653.6 13,644.4 13,678.233

Actual Wet Volumetric Flue Gas Flow Rate, acfm 22,259.1 22,341.2 22,474.7 22,358.333

Percent Isokinetic of Sampling Rate, % 102.4 100.4 101.8 101.533

F-Factor, dscfm/MMBtu @ %O2 0 0 0.000

Fw 0 0 0.000

Fc 0 0 0.000

Page 4 of 11
BSCP - Kiln Emission Test #2415

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Location Outlet of Control Device - Method 29

Average

Run Number 1 2 3

Test Date 12/21/2010 12/21/2011 12/21/2010

Run Start Time 7:25:00 AM 9:05:00 10:35:00 

AM

Run Finish Time 8:27:30 AM 10:07:30 AM 11:37:30 

Net Run Time, minutes 60 60 60

Dry Gas Meter Volume Sampled, dscf 43.324 43.864 43.395 43.528

Moisture Content of Stack Gas, % 4.62 3.90 5.65 4.723

Moisture Saturation at Stack Gas Temperature, % 100.00 100.00 100.00 100.000

Carbon Dioxide, % 2.3 2.3 2.2 2.267

Oxygen, % 17.4 17.3 17.6 17.433

Average Stack Gas Temperature, °F 262.88 269.21 266.75 266.280

Dry Volumetric Flow Rate, dry scfm 14,326.0 14,518.6 14,195.8 14,346.800

Actual Wet Volumetric Flue Gas Flow Rate, acfm 21,694.7 22,012.8 21,848.6 21,852.033

Percent Isokinetic of Sampling Rate, % 98.8 98.7 99.9 99.133

F-Factor, dscfm/MMBtu @ %O2 0 0 0 0.000

Fw 0 0 0 0.000

Fc 0 0 0 0.000

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BSCP - Kiln Emission Test #2415

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Emissions Summary

Location: Outlet of Control Device - Method 26A

Compound: Chlorine

Average

RunNumber 1 2 3

Mass_mg 1.2 1.2 1.2 1.20E+00

Eg/hr 2.48E+01 2.53E+01 2.49E+01 2.50E+01

ppm 3.60E-01 3.70E-01 3.65E-01 3.65E-01

ppm@7%O2 1.06E+00 1.03E+00 1.01E+00 1.03E+00

Compound: Hydrogen Chloride

Average

RunNumber

Mass_mg

Eg/hr

ppm

ppm@7%O2

Compound: Hydrogen Fluoride

Average

RunNumber

Mass_mg

Eg/hr

ppm

ppm@7%O2

Location: Outlet of Control Device - Method 29

Compound: Antimony

Average

RunNumber

Mass_mg

Eg/hr

mg/dscm

mg/dscm@7%O2

Compound: Arsenic

Average

RunNumber

Mass_mg

Eg/hr

mg/dscm

mg/dscm@7%O2

Compound: Beryllium

Average

RunNumber

Mass_mg

Eg/hr

mg/dscm

mg/dscm@7%O2

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BSCP - Kiln Emission Test #2415

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Compound: Cadmium

Average

RunNumber

Mass_mg

Eg/hr

mg/dscm

mg/dscm@7%O2

Compound: Chromium

Average

RunNumber

Mass_mg

Eg/hr

mg/dscm

mg/dscm@7%O2

Compound: Cobalt

Average

RunNumber

Mass_mg

Eg/hr

mg/dscm

mg/dscm@7%O2

Compound: Filterable Particulate

Average

RunNumber Outlet of Control Outlet of Control Outlet of Control 

Mass_mg 12/21/2010 12/21/2011 12/21/2010 1.20E+01

Eg/hr 1.4502768898356E- 3.49310134057023E 1.80352959826072E 2.25E-07

mg/dscm Filterable Particulate Filterable Particulate Filterable Particulate 0.00E+00

mg/dscm@7%O2 5.65E+01 1.38E+02 6.97E+01 8.81E+01

Compound: Lead

Average

RunNumber 1 2 3

Mass_mg 0.00285 0.00144 0.00116 1.82E-03

Eg/hr 5.65E-02 2.86E-02 2.28E-02 3.60E-02

mg/dscm 2.32E-03 1.16E-03 9.44E-04 1.47E-03

mg/dscm@7%O2 9.21E-03 4.48E-03 3.98E-03 5.89E-03

Compound: Manganese

Average

RunNumber 1 2 3

Mass_mg 0.00925 0.0124 0.00887 1.02E-02

Eg/hr 1.84E-01 2.46E-01 1.74E-01 2.01E-01

mg/dscm 7.54E-03 9.98E-03 7.22E-03 8.25E-03

mg/dscm@7%O2 2.99E-02 3.85E-02 3.04E-02 3.29E-02

Compound: Mercury

Average

RunNumber 1 2 3

Mass_mg 0.008304 0.008164 0.014004 1.02E-02

Eg/hr 1.65E-01 1.62E-01 2.75E-01 2.01E-01

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BSCP - Kiln Emission Test #2415

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mg/dscm 6.77E-03 6.57E-03 1.14E-02 8.25E-03

mg/dscm@7%O2 2.69E-02 2.54E-02 4.80E-02 3.34E-02

Compound: Nickel

Average

RunNumber 1 2 3

Mass_mg 0.00642 0.00566 0.00276 4.95E-03

Eg/hr 1.27E-01 1.12E-01 5.42E-02 9.77E-02

mg/dscm 5.23E-03 4.56E-03 2.25E-03 4.01E-03

mg/dscm@7%O2 2.08E-02 1.76E-02 9.48E-03 1.60E-02

Compound: Selenium

Average

RunNumber 1 2 3

Mass_mg 0.00725 0.00425 0.00465 5.38E-03

Eg/hr 1.44E-01 8.44E-02 9.13E-02 1.07E-01

mg/dscm 5.91E-03 3.42E-03 3.78E-03 4.37E-03

mg/dscm@7%O2 2.35E-02 1.32E-02 1.59E-02 1.75E-02

Page 8 of 11
BSCP - Kiln Emission Test #2415

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Process Run Data

Target

Run Name Value UOM Value Comments

1 Brick Produced (12/21/2010) 5.19 Tons/hr 5.19

1 Brick Produced (3/31/2011) 8.13 Tons/hr 8.13

2 Brick Produced (12/21/2010) 5.19 Tons/hr 5.19

2 Brick Produced (3/31/2011) 8.13 Tons/hr 8.13

3 Brick Produced (12/21/2010) 5.19 Tons/hr 5.19

3 Brick Produced (3/31/2011) 8.13 Tons/hr 8.13

APCD Run Data

Target

Run Name Value UOM Value Comments

1 DRY SCRUBBER 10 lime feed 0 lb/hr

2 DRY SCRUBBER 10 lime feed 0 lb/hr

3 DRY SCRUBBER 10 lime feed 0 lb/hr

4 DRY SCRUBBER 0 lime feed 0

1 BAGHOUSE 4.8 pressure drop 0 in/H2O

2 BAGHOUSE 4.8 pressure drop 0 in/H2O

3 BAGHOUSE 4.8 pressure drop 0 in/H2O

4 BAGHOUSE 0 pressure drop 0

Process Lab Run Data

Run Name Value UOM Comments

1 None 0

Page 9 of 11
BSCP - Kiln Emission Test #2415

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Sampling / Stack Data Results Detail

Location Outlet of Control Device - Method 26A

Average

Run Number 1 2 3

Test Date 3/31/2011 3/31/2011 3/31/2011

Run Start Time 11:40:00 AM 12:50:00 PM 2:00:00 PM

Run Finish Time 12:40:30 PM 1:50:30 PM 3:00:30 PM

Net Traversing Points 24 24 24

Net Run Time, minutes 60 60 60

Nozzle Diameter, inches 0.385 0.385 0.385 0.385

Pitot Tube Coefficient 0.84 0.84 0.84 0.840

Dry Gas Meter Calibration Factor 0.995 0.995 0.995 0.995

Barometric Pressure, inches of Mercury 28.7 28.7 28.67 28.690

Average Orifice Meter Differential, inches H2O 1.44 1.38 1.39 1.403

Dry Gas Meter Volume Sampled, cubic feet 39.208 38.532 39.135 38.958

Average Dry Gas Meter Temperature, °F 37.04 41.21 41.92 40.057

Dry Gas Meter Volume Sampled, dscf 39.899 38.879 39.391 39.390

Total Moisture Liquid collected, g 34.2 42 47 41.067

Volume of Water Vapor, standard cubic feet 1.61 1.98 2.21 1.933

Moisture Content of Stack Gas, % 3.88 4.85 5.31 4.680

Moisture Saturation at Stack Gas Temperature, % 100.00 100.00 100.00 100.000

Dry Mole Fraction 0.9612 0.9515 0.9469 0.953

Carbon Dioxide, % 6.9 3 3 4.300

Oxygen, % 16.2 15.9 15.9 16.000

Carbon Monoxide & Nitrogen, % 76.9 81.1 81.1 79.700

Fuel Factor 0.68 1.67 1.67

Dry Molecular Weight, lb/lb-Mole 29.75 29.12 29.12 29.330

Wet Molecular weight, lb/lb-Mole 29.29 28.58 28.53 28.800

Flue Gas Static Pressure, inches of H2O -8 -8 -8 -8.000

Absolute Flue Gas Pressure, inches of Mercury 28.11 28.11 28.08 28.100

Average Stack Gas Temperature, °F 312.63 312.33 312.88 312.613

Average Velocity Head, inches of H2O 9.7217342533 9.55712846 9.637447570 0.096

0469E-02 928908E-02 35954E-02

Average Stack Gas Velocity, feet/second 21.69 21.77 21.90 21.787

Stack Cross-Sectional Area, square feet 17.104 17.104 17.104 17.104

Dry Volumetric Flow Rate, dry scfm 13,736.7 13,653.6 13,644.4 13,678.233

Actual Wet Volumetric Flue Gas Flow Rate, acfm 22,259.1 22,341.2 22,474.7 22,358.333

Percent Isokinetic of Sampling Rate, % 102.4 100.4 101.8 101.533

Percent Excess Air, % 395.0 288.5 288.5 324.000

F-Factor, dscfm/MMBtu @ %O2 0 0 0.000

Round Duct Diameter, inches 56 56 56

Rectangular Duct Width, inches 0 0 0

Rectangular Duct Length, inches 0 0 0

Fw 0 0 0.000

Fc 0 0 0.000

Page 10 of 11
BSCP - Kiln Emission Test #2415

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Location Outlet of Control Device - Method 29

Average

Run Number 1 2 3

Test Date 12/21/2010 12/21/2011 12/21/2010

Run Start Time 7:25:00 AM 9:05:00 AM 10:35:00 AM

Run Finish Time 8:27:30 AM 10:07:30 11:37:30 AM

Net Traversing Points 24 24 24

Net Run Time, minutes 60 60 60

Nozzle Diameter, inches 0.4 0.4 0.4 0.400

Pitot Tube Coefficient 0.84 0.84 0.84 0.840

Dry Gas Meter Calibration Factor 0.995 0.995 0.995 0.995

Barometric Pressure, inches of Mercury 28.95 28.95 28.95 28.950

Average Orifice Meter Differential, inches H2O 1.73 1.77 1.74 1.747

Dry Gas Meter Volume Sampled, cubic feet 41.786 42.635 42.298 42.240

Average Dry Gas Meter Temperature, °F 32.44 36.31 37.67 35.473

Dry Gas Meter Volume Sampled, dscf 43.324 43.864 43.395 43.528

Total Moisture Liquid collected, g 44.7 37.8 55.2 45.900

Volume of Water Vapor, standard cubic feet 2.10 1.78 2.60 2.160

Moisture Content of Stack Gas, % 4.62 3.90 5.65 4.723

Moisture Saturation at Stack Gas Temperature, % 100.00 100.00 100.00 100.000

Dry Mole Fraction 0.9538 0.961 0.9435 0.953

Carbon Dioxide, % 2.3 2.3 2.2 2.267

Oxygen, % 17.4 17.3 17.6 17.433

Carbon Monoxide & Nitrogen, % 80.3 80.4 80.2 80.300

Fuel Factor 1.52 1.57 1.50

Dry Molecular Weight, lb/lb-Mole 29.06 29.06 29.06 29.060

Wet Molecular weight, lb/lb-Mole 28.55 28.63 28.44 28.540

Flue Gas Static Pressure, inches of H2O -8 -8 -8 -8.000

Absolute Flue Gas Pressure, inches of Mercury 28.36 28.36 28.36 28.360

Average Stack Gas Temperature, °F 262.88 269.21 266.75 266.280

Average Velocity Head, inches of H2O 9.7069146174 9.93225490 9.758274963 0.098

4374E-02 500056E-02 96724E-02

Average Stack Gas Velocity, feet/second 21.14 21.45 21.29 21.293

Stack Cross-Sectional Area, square feet 17.104 17.104 17.104 17.104

Dry Volumetric Flow Rate, dry scfm 14,326.0 14,518.6 14,195.8 14,346.800

Actual Wet Volumetric Flue Gas Flow Rate, acfm 21,694.7 22,012.8 21,848.6 21,852.033

Percent Isokinetic of Sampling Rate, % 98.8 98.7 99.9 99.133

Percent Excess Air, % 458.0 440.7 492.6 463.767

F-Factor, dscfm/MMBtu @ %O2 0 0 0 0.000

Round Duct Diameter, inches 56 56 56

Rectangular Duct Width, inches 0 0 0

Rectangular Duct Length, inches 0 0 0

Fw 0 0 0 0.000

Fc 0 0 0 0.000

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