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.com 
Entec 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•e 

1 

Detailed Test Results 3 

Sampling Prcccduro•. 7 

Location of Test Ports 

Particulate Sampling Train 

Particulate Field Data Sheets 

11 

12 

13 

Control Room Process Data 23 

Quality Control I Quality Assurance Procedures 

QA/QC Checklist 

Orifice and Temperature Check 

Cyclonic Flow and Preliminary Data 

25 

30 

31 

34 

Particulate and Flow Equipment Calibrations 36 

Laboratory Analysis 

-Summary of Results 

-Narrative Summary 

-Sample Custody 

5O 

51 

55 

60 

Test Calculations and Nomenclature 63 
Executive 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 samples 
0 

0 0 

o • 
Detailed Test Results 
Entec,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 

1 

2 

3 

4 

5 

26A 

26A 
ENTEC 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 

Pg 

Cp 

Y 

Dn 

Wlmp 

O• 

HCL 

HF 

Militap/Time 

mi• 

Ft 

in. Hg 

in. H=0 

in. H• 

inches 

dcf 

in. Hz0 

grams 

grams 

% 

F 

mg 

mg 

mn mg 

05116106 

0830-0937 

60 

22.166 

29.72 

0.06 

0.84 

0.994 

1.850 

0.300 

40.057 

75.3 

1.55 

76.0 

9.0 

16.0 

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 

26.8 
ENTEC 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 1.0252 
Sampling Procedures 
Procedures 

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 was maintained 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:. 

8.25 

12 

6 

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 Stack 
Run No. I 

Field Data Sheets 
ENTEC 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 •aCK Temp (;F Meter Temp (°F) 

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 

361 

362 

362 

350 

362 75 

362 78 

361 80 

363 81 

363 82 

360 

360.8 

83 

75.3 

Run No. 2 

-F ield Data Sheets 
ENTEC 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 

1-2 

1-3 

1-4 

1-5 

1-6 

2-1 

2-2 

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 

87 

89 

90 

90 

90 
II 
Run No. 3 

Field Data Sheets 
ENTEC 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 

4.90 

2-4 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 90.5 
o •O A 

oEEE 

E 0 

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Control Room Process Data 
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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. 

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Webmail Help 

Jim Owens 

Original 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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