ENTEC Services Pollution Control System Evaluation

and Source Emissions

Testing Cherokee Brick

and

Tile Macon, GA Compliance Emissions

Testing No. 1 & No. 2 Dry Lime Adsorber

Stack

May 16, 2006 Entec Project No.i 26141

dUN -2 •,08 ![[ .::

16-D Commerce

Avenue Hueytown,

Alabama 35023 Phone: (205) 491-6676

Fax (205) 491-6614 www.entecservices.comEntec Services,

Inc. 16•D Commerce

Avenue Hueytown, Alabama

35023 Telephone: (205) 491-6676 Fax: (205) 491-6614 Results of the May 16, 2006 Emissions Testing

on No. 1 & No. 2 Dry Lime Adsorber

Stack

at the Cherokee Brick Facility

in Macon, Georgia
Submitted to: Cherokee E•rick

& Tile Co. 3250 Waterville

Road Macon, Georgia

31206 Attention: Mr. Jim Owens
Entec Project No. 26141 Completed By: •.n•.Beane r•anager Report Submitted:

June 2, 2006 Reviewed By: --// John T. Sutton QA / QC 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.Section Cherokee

Brick

& Tile Co. Table of Contents
Executive Summary Pa•e1 Detailed Test Results 3 Sampling Prcccduro•. 7 Location of Test Ports Particulate Sampling

Train Particulate Field Data Sheets 111213 Control Room Process

Data 23 Quality Control

I Quality

Assurance

Procedures QA/QC Checklist Orifice and Temperature

Check Cyclonic Flow and Preliminary

Data 25303134 Particulate and Flow Equipment

Calibrations 36 Laboratory Analysis -Summary of Results -Narrative Summary -Sample Custody 5O515560 Test Calculations

and Nomenclature 63Executive Summary Cherokee Brick located

in Macon,

Georgia,

retained

Entec Services,

Inc. to perform emissions testing on the No. 1 & No. 2 Kiln stack. Mr. Lynn Beane,

Mr. Art Otero, and Mr. Ryan Harris, of Entec Services,

Inc. conducted

the testing on May 16, 2006. Representing Cherokee Brick was Mr. Jim Owens

who coordinated

testing

with the control

room production activity.

Mr. Daniel McCain

represented

the Department

of Natural

resources, Environmental Protection

Division

Air Branch

from Atlanta,

Georgia,

during the testing. Entec Services,

Inc. encountered

no difficulties

in the field collection

of the samples

or in the laboratory

analysis

of the samples0 0 0

o •Detailed Test

ResultsEntec,Se vices,-tnc SOURCE OVERVIEW

SOURCE OWNER: PLANT LOCATION: SOURCE(S) NAME(S): SOURCE(S) CONDITION: SOURCE(S) SHAPE: PROBE WASH CHEMICAL: SOURCE PERMIT NUMBER: TEST PERFORMED: ADDITIONAL TEST REQUIREMENTS: REFERENCE METHOD

TESTS:

PROJECT MANAGER ENVIRONMENTAL ANALYST

PROJECT

LEADER ENVIRONMENTAL ANALYST-ASSISTANT OWNER'S REPRESENTATIVE: RULING AGENCY: RULING AGENCY

REPRESENTATIVE: DATES TESTS CONDUCTED: ENTEC PROJECT

NUMBER: Cherokee

Brick and Tile Macon, GA PCDO1 Stack Annual Compliance

Testing Circular Acetone 3251-021-0167-V-02-0 Lime MACT Subpart JJJJJ Minimum Particulate

Requirements

30 dscf Sample Location Volumetric Flow Molecular Weight Moisture Content Particulate Hydrogen Chloride Hydrogen Fluoride

EPA Method EPA Method EPA Method EPA Method EPA Method EPA Method EPA Method Mr. Lynn Beane Mr. Art Otero
Mr. Ryan Harris Mr. Jim Owens Georgia Department

of Natural Resources Mr. Daniel McCain 05/16/06 26141 1234526A 26AENTEC Services,

Inc. 16-D Commerce Ave. Hueytown, Alabama 35023 INPUT TEST DATA Client: Source: Cherokee

Brick and Tile PCDO1 Stack 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 Impinger Weight Gain (Moisture) Oxygen Concentration,

dry basis Carbon Dioxide Concentration,

dry basis •vg. Sq. Rt. of Delta P Stack Temperature total Hydrogen

Chloride collected,

mg total Hydrogen

Fluoride collected,

mg total particulate

collected Job No.: Data Input By: Symbol Units

I

2

PgCp
Y

Dn

Wlmp

O•

HCL HF Militap/Time mi• Ft in. Hg in. H=0

in. H• inches dcf

in. Hz0 grams grams %

Fmgmgmg mn

05116106 0830-0937 60 22.166 29.72 0.06 0.84 0.994 1.850 0.300 40.057 75.3 1.55 76.09.016.0

05116106

26141 Art Otaro Test Data 3 051161O6 1019-1124 60 22.166 29.72 0.07

0.994 1.850 0.300 41.058 86.0 1.56 68.0 14.0 16.5 6.0 6.0 0.567 0.563 360.8 20.2 364.3

1204-1308

4.6 29.9 60 22.166 29.72 0.08 0.84 0.994 1.850 0.300 42.237 90.5 1.69 78.0 12.3 16.5 4.0

AVERAGE

29.72 0.07 0.84 0.994 1.850 0.300 41.117 83.9 1.60 74.0 11.8 16.3 5.3 0.586 0.572 365.3 363.4 20.3 22.0

20.8 4.7 5.1 26.3 24.1

4.8 26.8ENTEC Services,

Inc. 16-D Commerce Ave. Hue•vn• Alabama 35023 CALCULATED TEST DATA Client: Cherokee Brick and Tile Source: PCDO1 Stack DelcripUon Run Number Formulas

Symbol

Unlta

Test Date Time Began-Ended 1. Stack Pressure 2. Meter Pressure 3. Standard Meter Volume
•.•. S•."•.-•."d Vc!u..-.¢ • Wctc• V•,, 17.64- Y= (v•/'r•)" (p• • t3.(

4b. Standard Volume of Water Collected in Silica Gel =0.0471•w,• 5. Molature Fraction 8. Moisture FraclJon (• Saturation (Theorel/cal) 9. Molecula• Weight Of Stack Gas, dry basis 10. Molecular Weight Of Stack Gas, wet basis 11. Average Stack Gas Velocity 12. Stack Gas Flow • Stack Conditions

=(V,•,• V.._.•_•.V(V,•

V V,,•=•.• 0.a•lO•p 0.,M*(CO=p0.•'(•00-(O•HCO• 8•.49*cp*(sqn &P)=•I'SQRT((TJ

(P

13. Stack Gas Flow • Standard Conditions 14. Stack Gas Flow •} Dry Standard Conditions 14b. Hydrogen Chloride concentration •]• Std+Cond..Grains/Cu.Ft. 14b. I-lydro•en Fluoride concentration • Std.Cond.,Grains/Cu.Ft. 15. Particulate concentmlion @ Standard Conditions 15b. I-h/dro• Chlodde emissions, Ibs per hour =(0.01543"HF,•VQ,• =(s0rt000)'HCLO•'Q• 15b. Hydrogen Fluodde emissions, Ibs per hour 21. Particulate emissions 22. Volume collected through noz:de 23. Particulate concentration,

(• actual conditions 24. Isokinetlc Sampling Rate, Percent =T=/P,'(0.00Z•V•¢+

V.'*t•P,=/T.

100*Vnl

Post Meter Orifice Cal. (EMC ALT-00S Yqa) Difference, (Calibration must be within 5% of odgina! Y-factor) Job No.:

26141 Data Input By:. Art Otem Calculated r•, 2 3 AVERAGE 05/16/06 05/16/06

05/16/06 Mird• Tmte 0830-0937

1019-1124

1204-1308 P, i•. h• 29.72

29.73

29.73

29.73 P. lit. H¢ 29.83

29.83

29.84

29.84 V,,•,• • 39.149

39.338

40.149

39.545 v=...,_,_ =of 3.6//

3.200

3.671

3.482 v,,,• =of 0.424

0.660

0.580

0.555 B, 0.0927

0.0894

0.0957

0.0926 TB• • 10.0123

10.4527

10.5918

10.3522 • •tC-r•o•

29.600

29.620

29.300

29.507 B= e/•m•,=

28.524

28.582

28.218

28.441 v, •t/= 40.06

39.81

41.71

40.531 O, acf• 53,282

52,952

55,479

53,904 O• =¢• 34,039

33,686

35,248

34,324 O• ds•m 30,883

30,676

31,873

31,144 HCL• grta.•f

0.008

0.508

0.008

0.008 HFc$ •bcJ

0.002

0.002

0.002

0.002 ¢., gr/d•f 0.0118

0.0103

0.0093

0.0105 HCl 4b•hr Ib•r

2.11

2.09

2.30

2.17
m • •

0.48

0.48

0.54

0.50 PaR IMtr 3.12

2.71

2.53

2.79 v,, a•f 67.544

67.906

69.885

68.445 c, ¢r•a,;f 0.0068

0.5060

0.0053

0.0060 % 95.40

96.51

94.80

95.57

1.0260 1.0145

1.0351

1.0252Sampling ProceduresProcedures The particulate,

hydrogen

chloride,

and hydrogen

fluoride

on the Brick Kiln Dry-Bed Scrubber Exhaust

were determined

by EPA Methods

1-5, and 26A of the CFR Title 40, Part 60, and Appendix

A. The calibration

and quality assurance

procedures

of EPA CFR 40 Part 60 Appendix

A Methods

1-5, and 26A of the "Quality

Assurance

Handbook for Air Pollution

Measurement

System"

Volume

III Stationary

Source-Specific

Methods were followed

throughout

the duration

of the field testing and laboratory

analysis.

The most current

CFR revision

of each method

(July 1, 2004) were used. The following paragraphs summarize

the methods

that were used for this project.

Mr. Daniel McCain from the State of Georgia

Department

of Natural

Resources

Air Protection

Branch provided two (2) audit samples

for HCI analysis

in conjunction

with the three (3) compliance test runs. Stack Gas Volumetric

Flow The velocity

of the gas stream

was determined

according

to EPA Reference

Method

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

2. Stack Gas Molecular

Weight The carbon dioxide

and oxygen

concentrations

were determined

using EPA Reference Method 3. A grab sample

of the flue gas was extracted

from the gas stream

during each particulate

test run and analyzed

using a Fyrite analyzer.

The molecular

weight of the gas was calculated

using the moisture,

oxygen

and carbon

dioxide

content

and the measured stack gas temperature.

The Fyrite sampling

system

will be verified

to be leak free prior to the analysis.Hydrogen Chloride

I Fluoride

with Particulate Preliminary data will be used to determine

stack temperature,

pressure,

and range of velocity heads, moisture

content

and stack gas dry molecular

weight prior to sampling. The meter box was leak checked

from the pump to the orifice.

Initial and final leak checks of the sampling

system

and pitot lines were performed

as outlined

in Method

5 and were recorded

on the data sheets.

The nozzle (glass with an angle of taper of 30 degrees and of button hook design)

was calibrated

before and after the test using a micrometer and was also recorded

on the field data sheets. The sampling

probe was placed at each sampling

point to provide

a total sampling

time of at least 60 minutes

and a volume

of at least 31.8 cubic feet. The gases were drawn through a glass nozzle attached

to a heated

glass lined probe.

The probe wasmaintained at the proper

setting

to obtain a temperature

of > 248 0 F. The gases then proceeded through

borosilicate

glass filter holder, with a Teflon frit filter support

through a tarred Teflon or quartz fiber filter to remove

particulate

matter.

The exit of the filter was maintained

at a temperature

of > 248 0 F. These temperatures

were recorded

at each point on the field data sheets. The gases were then scrubbed

through

a series of four impingers

to capture

hydrogen halides, and moisture.

The optional

moisture

knockout

impinger

was not used in the sample train. The first and second

impingers

contained

approximately

100 ml of a 0.1N H2SO4 solution

and the third and fourth impingers

contained

approximately

100 ml Of a 0.1 N NaOH solution.

(Entec modified

the impinger

train to only contain

one NaOH impinger since the halogen

components

were not to be analyzed.)

The fifth impinger contained pre weighed

silica gel to remove

any remaining

moisture.

The gases passed through the impinger

series in an ice bath to maintain

a maximum

exit temperature

of 68 0 F. This temperature

will be also recorded

on the field data sheets.

The clean and cool gases then entered

the meter box where the gas flow and temperature

were measured.After the completion

of each test run leak rate determinations

were made and recorded on the field data sheets.

Then the sampling

train and the probe nozzle assembly

were transferred to the cleanup

area making

sure no particulate

was lost. The cleanup

data was also recorded

on the field data sheets and / or the laboratory

checklist

sheet. Particulate catches

were placed

in sealed petri dishes.

Each acetone

rinse from the nozzle, probe, and filter holder were combined

and placed in a sealed container.

The first, and second

impinger

contents

were transferred

to its tarred container,

weighed and the rinsing from the glassware

will be added to this container.

The third impinger contents were weighed

for moisture

determination

calculations

but were not kept for analysis. The silica gel from the fourth impinger

was transferred

to its respective

tarred container and weighed.

For the group of tests an acetone

blank, sulfuric

acid solution, distilled water and acetone

of approximately

200 milliliters

were placed

in a sealed container. These containers

will be clearly marked

and transported

to the laboratory

for analysis. Enthalpy will perform

all of the laboratory

analysis

and is an approved

Louisiana accredited lab .(Certification

Number

04010)

that meets all requirements

for the State of Georgia approved

and accredited

laboratory.Entec Services,

Inc .1..•.•..C...0..m..m..erce Ave. Hue .•___0__w.n AL 35023
:,.......••,...•.,;;.;... STACK DRAWING

& TRAVERSE

POINT LOCATION Client: Cherokee

Brick and Tile Job No. 26141 Source: PCDO1 Stack Input By: Art Otero Type of Traverse: Velocity (V) •x Particulate

(P): Stack Diameter, inches:

63.75 Stack Height, filet:

100

P

Port Type

Flange

Port Diameter

6.0" Stack Area, Ft•: 22.166 Number of Ports: 2 Stack Properties:

Inches

Duct Diameters Upstream Disturbance:

170.0

2.67 Downstream Distudoance:

634.0

10.73

Length of Port, Inches: Total Number of Traverse Points: Number of Points per diameter:. 8.25126 63.8 •NCHeS

170.0

INCHES

684.0 INCHES Inside Stack

Outside Nipple Point N(x

Inches Inches 1 2.8 11.1 2 9.3 17.6 3 18.9 27.1 4 44.9 53.1 5 54.4 62.7 6 60.9 69.2

Adjustsd points diameter • 24" no point closer than 1.0 inch Adjusted points diameter < 24" no point closer than 0.5 inch Stack Diameters between 12-24 inches minimum points are 8 4 points per port if the 8 2 diameters downstream

and upstream criteda is met.Method 5/26A

Sampling Train

Fi!ter EXit T•mperature lmpinger Exit Temperature (<68 F)

Ice Bath

Exhaust

1 ?Particulate Field

Data

Sheets No. 1 & No. 2 Dry Lime

Adsorber

StackRun No.

I Field Data

SheetsENTEC Services,

Inc. 16-D Commerce Ave. Hueytown, A/abama 35023 Client: Cherokee

Brick and Tile Test Date:

5/16/2006 Source: PGDO1 Stack Run Number:

1

PARTICULATE FIELD DATA, EPA METHOD

5

1-1 0.33 ut,,-, H

Temp (;F

Temp (°F) •aCK Meter 0.5745 1.58

360

65 1-2 0.36

0.6000

1.73 1-3 0.36

0.6000

1.73 1-4 0.30

0.5477

1.44 1-5 0.29

0.5385

1.39 1-6 0.24

0.4899

1.15 2-1 0.35 2-2 0.35 2-3 0.30 2-4 0,33 2-5 0.35

K'Factor 4.80

0.5916

1.68 0.5916 1.68 0.5477 1.• 0.5745 1.58 0.5916 1.68 2-6 0.31

0.5568

1.49

0.32 0.5670

1.55

363 361362362350362

75 362 78 361 80 363 81 363 82 360

360.8 83

75.3Run No.

2 -F ield Data

SheetsENTEC Services,

Inc. 16-D Commerce Ave. Hueytown, AJabama 35023 Client: Cherokee

Bdck and Tile Test Date:

5/16/2006 Source: PCDO1 Stack Run Number:

2

PARTICULATE FII=! rl DATA, EPA METHOD 5 ::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: Traverse Point

Delta P

Sq. Rt. Delta P

I•1•, H

•,-=, •'-_.•.=. ,o:• 1-1 0.27 1-21-31-41-51-62-12-2 0.37 0.30 0.34 0.34

K-Factor 0.28

0;5292 0.36 0.6000 0.38 2-3 0.36 2-4 0.30 2-5 0.27 2-6 0.25

4.90 0.32 r'| "1

==.p.| 0.5196 1.32

364

80 0.6083 1.81

364

81 0.5477 1.47

365

82 0.5831 1.67

365 0.5831 1.67

365

85 1.37 358

86 1.76 366

87 0.6164 1.86

366 0.6000 1.76

367 0.5477 1.47

367 0.5196 1.32

364 0.5000 1.23

360

85

8789909090IIRun No.

3 Field Data

SheetsENTEC Services,

Inc. 16-D Commerce Ave. Hueytown, Alabama 35023 Client: Cherokee

Brick and Tile Test Date:

5/16/2006 Source: PCDO1 Stack Run Number:.

3

PARTICULATE FIELD DATA, EPA METHOD

5

T•w• Foi.t

Deita P

Sq. K't. Deita P

•eUa H

Stack Temp. (°F) Meter Temp. (°F) 1-1 0.39

0.6245

1.91

366

85 1-2 0.40

0.6325

1.96

366

86 1-3 0.37

0.6083

1.81

366

88 1.67 366

90 1.57 365

90 1-4 0.34

0.5831 1-5 0.32

0.5657 1-6 0.28 2-1 0.41 2-2 0.37 2-3 0.32

0.5292

1.37 0.6403 2.01 0.6083 1.81 0.5657 1.57

K-Factor 4.902-4 0.30

0.5477

1.47 2-5 0.33

0.5745

1.62 2-6 0.30

0.5477

1.47

0.34 0.5856

1.69

365

90 365 91 365 92 366 93 365 93 365 94 364 94

365.3 90.5o •O A

oEEE

E 0

• •,o o• oControl Room

Process

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Rept Subject: Re: Production

Data From: "Jim Owens" <jim.owens@cherokeebdck.corn> •j1 Date: Fri, June 2, 2006 10:50 am Priority: Normal Options: View Full Header Viow Printable Version

Ar t, Lingl No. 1 was on a 23 car/day

push rate with Queen size brick.There

% 8640 brick/car

at 3.60 pounds/brick. Lingl No. 2 was on a 22 car/day

push rate with Modular

size brick.There 8064 brick/car

at 3.60 pounds/brick. If you need anything

else,please

let me know. Refresh Folder List Administer My Account Empty Trash Webmail Help Jim OwensOriginal

Message From: <aotero@entecservices.com> To: <jim.owens@cherokeebrick.com> Cc: <ibeane@entecservices.com>; <tkeiy583@yahoo.com>; <aotero@entecservices.com> Sent: Thursday,

June 01, 2006 5:54 PM Subject: Production

Data

>>>>>>>>>>>>>>> Jim we seem to have misplaced

the production

data from the testing

wE on May 16. Could you e-mail that to me or Lynn. If you have any quest just give me a call. Art Otero Environmental

Analyst

III Entec Services,

Inc. 16-D Commerce

Ave. Hueytown, AL 35023 (c)205-960-1502 (o)205-491-6676

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