E•ncv- pi•÷ Z V_ihq P2,01 

Entec Sewices, Inc. 

16 D Commerce Avenue 

Hueytown, Alabama 35023 

Telephone: (205) 494-6676 

Fax: (205) 491-6614 

Results of the January 17 and 18, 2006 

RATA/Compliance Testing for Gaseous Emissions on the 

Brick Plant No. •2 Tunnel Kiln located in 

Sugarcreek, Ohio 

Facili• Permit No. 06-79-00-0118, tD No. P201 

Submitted to: 

Belden Brick Company 

475 Dover Road 

Sugarcreek, Ohio 44681 

Attention: Mr. John Jonson 

Entec Project No. 26108 Report Submitted: Februa• 18, 2006 

C pleted, •y: 

e )om£y Lo Jr. 

Project Leader 

evlewed By: 

Tom Lotz Sr. 

QA/QC Manager/Project Manager 

hereby certify to the best of my knowledge all field sampling and laboratory anaiysts pe•rmed for 

this report is authentic and accurate. It has been checked for completeness and accuracy, 
Belden Brick Company 

Table of Contents 

Section 

Executive Summary 

Compliance Emissions Summary 

Detailed Test Results 

Relative Accuracy Test Results 

Sulfur Dioxide 

Nitrogen Oxides 

Carbon Monoxide 

Hydrogen Chloride 

Hydrogen Fluoride 

Sampling Procedures 

Location of Test Ports 

Diagram of Sampling Train 

RATA RM and CEM's Field Data 

Volumetric Flow Field Data 

Production Data 

Quality Assurance/Quality Control Procedures 

Preliminary Traverse w/Cyclonic Flow 

Analyzer Interference Checks 

NOx Converter Efficiency Test 

FT-IR CTS Check 

Instrumental Analyzer Calibrations 

Calibration Gas Certificates 

Flow Equipment Calibrations 

Nomenclature and Te• Calc.utations 

Page No. 

3 

6 

8 

14 

15 

16 

17 

18 

19 

20 

25 

26 

28 

t33 

156 

159 

166 

167 

173 

175 

176 

196 

207 

210 
Executive Summary 

Entec Services, Inc. was retained by Belden Brick Company to perform a RATA on the 

CEM unit and compliance gaseous emissions testing on Brick Plant No. 2 Tunnel Kiln 

located in Sugarcreek, Ohio. The control devices for the kiln are a dry scrubber and a 

baghouse. The Opsis CEM is composed of two analyzers, One analyzer uses an infrared 

(IR) detector and the other used an ultraviolet (UV) detector, The IR detector analyzes the 

gas stream fo• NOx, CO and SO2. The UV detector measures HCl and HE Both 

analyzers shoot the IFL/UV across the stack to let the gas combine with the projected light 

source. A detector at the other side of the stack picks up the light source influenced by 

the gas stream and transmits via fiber optic cable the signal to be processed by a 

interferometer located with the signat processing equipment in the cabinet. This "spectra" 

is then turned into a direct ppm measurement. 

Mr. Erik Groth and Mr. Tommy Lotz, Jr. of Entec Services, lnc conducted the testing on 

January 17 and 18, 2006. Mr. John Jensen was present from Belden Brick and to 

coordinate testing with control room activities. Mr. Todd Brown from the State of Ohio 

Environmental Protection Agency observed these tests, 

The first through fourth RATA runs failed the spike and recovery procedure for the reactive 

gases (HC1 and HF) and were considered invalid. The numbering system for the reactive 

gases was then restarted. The sixth reactive gas run was also considered invalid due to 

the failure of the spike and recovery procedure. The sixth run was restarted, The restarted 

runs one through three of the HCI were valid but were not used in the calculations. 

Seventeen 30-minute RATAs were performed. Due to the confusing nature of the 

numbering system a chart has been constructed to clarify the test program and is included 

on the following pages. Entec Services, tnc encountered no other difficulties in the field 

collection of the samples or in the laboratory analysis of the samples. 

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

each paired test run compared to the maximum emission limits set forth by the State of 

Ohio Environmental Protection Agency. Tests results indicate the average gaseous 

emissions are below the limits set forth by the State of Ohio EPA for Facility Permit 

No, 06-79-00-0118, Facility Source Identification No. P201. 
The RATA test summaries on the following pages give a summary, of the. CEM's calculated 

emissions, reference method calculated emissions and the calculated relative accuracy for 

the CEM•s emissions, Test results indicate that the RATA results are below the limits 

for $02, NOx, HF and HCl and above the limits for CO as set forth by the Code of 

Federal Regulations (CFR) 40 Pad: 60, Appendix B, and Performance Spe¢ifl(•attons 

2, 4, (•, and 1'5, 
Plant 2 

CEMS 

HCI and HF Plant 

FT-IR Flow 

Notes 

HF/HCI Scratch Spike and Recovery Bad: 

HFIHCI Scratch Sp!,ke and ReCOvery Bad 

HF/HCI Soratch Spik e an,d Recovery Bad 

•=tHCI S•ratoh Spike gnd ,Recovery Ba,,d, 

HCI not used 

not; used 

Run No. Run No, Start Stop Date 

HCI not used 

Spike and ae•ve• Bad 

8 

9 

t0 

11 

12 

t 0910 

2 1020 

3 t130 

!255 

1442 

6 1616 

7 0650 

0620 

1109 

1700 

t912 

2002 

2055 

2141 

2228 

4 

5 

8 

9 

11 

12 

13 

14 

1 ̧5 

17 

0940 1117/2006 

1050 1/t 7/2006 

,!,•00 1t1712006 

1325 111712006 

1512 1/17/2006 

t646 ,,!/!7/2006 

0720 1/18/2006 

0850 111812006 

1030 1It 8t2006 

1139 1f18/2006 

1-•3,• 1/!8/2oo6 

18•6 1:i18/2006 

1942 t/t8•2006 

2032 1/18/2006 

2t25 1t18/2006 

2211 1118/2006 

2258 t118/2006 

5 

C 

SOURCE OWNER: 

PLANT LOCATION: 

SOURCE(S) NAME(S): 

SOURCE(S) CONDITION: 

SOURCE(S) SHAPE: 

SOURCE PERMIT NUMBER: 

TEST PERFORMED: 

REFERENCE METHOD TESTS: 

Entec Sewices, Inc. 

SOURCE OVERVIEW 

Beiden Bdck 

Sugarc•eek, Ohio 

Bdck Plant Tunnel Kiln No. 2 

Initial RATA/Compliance 

Circuit 

0679.000-t18-P301 

RATA T• 

Sample Location 

Volumetric Row 

Molecular Weight 

Sulfur Dioxide 

O•es of N•ogen 

•on Monoxide 

Hy(trogen •lodde 

Hydrogen F|uodde 

PROJECT MANAGER 

ENVIRONMENTAL ANALYST PROJECT LEADER 

ENVIRONMENTAL ANALYST ASSISTANT 

OWNEWS REPRESENTATWE: 

RULING AGENCY 

RULING AGENCY REPRESENTATIVE: 

DATES TESTS CONDUCTED: 

ENTEC PROJECT NUMBER: 

Mr. Tom Lotz, St, 

Tommy •, Jr. 

Mr. Edk Gro•.h 

Mr. John Jensen 

O•oEPA 

Todd Brown 

0tll 7t06 011t 8106 

261O8 

EPA Method 

EPA Met,hod 

EPA Met,hod 

EPA Method 

EPA Method 

EPA Method 

EPA Method 

EPA Method 

i 

2/Spec 6 

3 

7EiS•Band2 

10 / S•6 and 4 

320 / Spec 6 and 15 

320 / Spec 6 and 15 





0 


E 

0 


Procedures 

The relative accuracy test results and the emission tests were determined using EPA 

Methods 1, 2, 3A, 4 (by FT-IR), 6C, 7E, and 10 CFR Title 40, Part 60, Appendix A; Method 

320 CFR Title 40, Part 63, Appendix A; Appendix B performance specification 2 for Sulfur 

Dioxide and Oxides of Nitrogen, performance specification 4 for Carbon Monoxide, 

performance specification 6 for flow rates, and performance specification 15 for Hydrogen 

Chloride and Hydrogen Fluoride. The calibration and quality assurance procedures of 

EPA CFR 40 Part 60 Appendix A for all methods, and the "Quatity Assurance Handbook 

for Air Pollution Measurement System" Volume lit Stationary Source-Specific Methods 

were followed throughout the duration of the field and laboratory testing. 

The most current revision revised as of July 1, 2004, of each method (as described in the 

Federal Register) was used. 

To satis• the certification requirements for the CEMS data accuracy assessment of the 

applicable performance specifications in 40 CFR 60, Appendix B, the relative accuracy 

test must have a minimum of nine test runs. If more than 9 test runs are performed a 

maximum of three sets of the test results may be rejected so long as the total number of 

test results used to determine the relative accuracy is greater than or equal to nine. 

However, all data must be reported including the rejected data. The relative accuracy 

performance specification of the CEM'S must be no greater than 20 percent of the mean 

value of the reference data in units of the emission or 10 percent of the applicable 

standard, which ever is greater. Each run was twenty-one minutes tong. 

Stack Gas Volumetric Flow 

The velocity of the gas stream was determined according to EPA Reference Method 1 and 

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 1. 
Stack Gas Molecular Weight-Instrumental 

The carbon dioxide concentrations were determined using EPA Reference Method 3A. 

The molecular weight of the gas was calculated using the moisture, oxygen and carbon 

dioxide content and the measured stack gas temperature. 

Moisture Con•nt 

The moisture content used for calculating the gas stream flow rate was determined by 

measuring the amount of moisture using a Temet DX 4000 FT-IR analyzer. 

Oxv_clen 

The oxygen content in the flue gas was determined using a Siemens Oxymat 61 oxygen 

analyzer. The Oxymat 61 uses paramagnetic analysis. Oxygen is attracted into a strong 

magnetic field. Oxygen molecules in an inhomogeneous magnetic field are drawn in the 

direction of the increased field strength due to the paramagnetism When two gases with 

different oxygen concentrations meet in a magnetic field, a pressure difference is 

produced between them. One of the gases is a reference gas (N2), the other is the sample 

gas. The reference gas is introduced into the sample chamber through two channels. One 

of these reference gas streams meets the sample gas within the area of a magnetic field. 

Because the two channels are connected, the pressure, which is proportional to the 

oxygen concentration, causes a flow. This flow is converted into and electric signal by a 

microflow sensor. This current is then amplified and provides a signal output of 4-20ma 

signals, which corresponds to a full-scale range of 0-25% oxygen. 

Carbon Dioxide 

Carbon dioxide concentrations were continuously measured with a Siemens Ultramat 23 

non-dispersive infrared (NDIR) analyzer. The theory of operation for this ana•zer is 

based on the principle that CO2 has a unique absorption line spectrum in the infrared 

region. The instrument consists of an infrared light source, a chopper, a measurement 

cell, and a detector. The infrared light beam emitted by the source passes through the 

measuring cell, which is filled with a continuously flowing gas sample. The light beam is 

partially absorbed or attenuated by the gas species of interest in this cell before reaching 

the front chamber of the detector, Both the front and rear chambers of the seaied detector 

are filled with a reference gas. The difference in the amount of light absorbed between 

the front and rear chambers are dependent on the concentration of the gas species of 
interest wffhin the sample measurement cell; a pressure differential is thus created 

between the two chambers. This pressure difference is then observed as gas flow by the 

micro-flow sensor located in a channel connecting the two chambers. The resulting AC 

signal from the micro-flow sensor is rectified, amplified and linearized into a 4-20ma signal 

for output that corresponds to a full-scale 0-25% measurement range. 

Sulfur Dioxide 

A Western Research Model 721-AT SO2 analyzer provided continuous analysis of SO2 in 

the gas stream. The basic analytical principle involves quantitative measurement of the 

absorption of UV radiation by SO2 molecules. The analyzer uses a single light source, 

which emits an appropriate wavelength, illuminating the sample all through which the 

sample is continuously passed. Narrow-band optical filters are rotated through the beam, 

and the radiation passed through the optical filters and sample cell is detected by a single 

photo-detector. The signal pulses from the photo-detector are separated by a multi-plexor 

into a measuring channel and a reference channel, A log ratio amplifier computes the 

logarithm of the input signal ration, producing a signal that is proportional to the SO2 

concentration. The duaI-range analyzer has a digital readout, as well as 0-10.0 V DC 

output terminals. The full scale of the instrument was set at 200 ppm. 

Nitrogen Oxides 

An Advanced Pollution Instruments (API) Model 200AH NO× analyzer, which operates on 

the basis of chemiluminescences, was used continuously to determine the NOx 

concentration in the effluent. The sample is initially routed through a converter where the 

NO2 iS dissociated to form NO. The sample is then passed through a reaction chamber 

where the NO is quantitatively converted to NO2 by gas-phase oxidation with ozone 

produced within the analyzer. In this reaction, the NO2 molecules are elevated to an 

electronically excited state and then immediately revert to a non-excited ground state. 

This reversion is accompanied by emission of photons (luminescent light), which impinge 

on a photo-multiplier detector and generate a low-level direct current. The NOx 

concentration measured by the instrument includes the contributions of both the NO in the 

effluent and the NO resulting from the dissociation of NO×. Instrument outputs include an 

analog readout and 0-10 V DC output terminals. Full-scale response of the analyzer was 

set at 25 ppm throughout the test period. 
Carbon Monoxide 

The CO emissions were measured using a Siemens Ultramat 23 analyzer. This monitor is 

a selective non-dispersive infrared radiation (NDIR) gas analyzer that operates on the 

infrared double-beam alternating light principle. The full range for the CO component of 

this instrument throughout the test period was 1000 ppm. 

Hydrogen Chloride and Hvdroaen Fluoride 

Emission measurements for HCI and HF were performed using the Temet DX 4000 FT-IR 

in accordance with Performance Specification 6 and 15. Twelve 30-minute runs were 

performed for the RATA. Nine of these runs satisfied the emissions portion of the test as 

per Performance Specification 6 and 15. Spike and recoveries were performed before and 

after each run to validate the accuracy of the analyzer and sampling system to correctly 

measure reactive compounds (HCI, HF). This spike and recovery technique was 

performed as specified in Method 321. A total of t0 three-minute samples were collected 

per each 30 minute run. The sampling system turned over the cell volume 18 times per 

three-minute sample. This flow rate satisfied the measuring time/rate as set by 

performance specification 15. 

Samplin_• System 

Samples were extracted from the gas stream by a heated titanium probe maintained at a 

set temperature of 200 degrees Celsius, through a one-hundred (100) foot heated sample 

line that was heated to a temperature of 200 degrees Celsius, then pulled through the FTIR by a chi|led sample conditioner to remove the moisture in the gas stream and then 

delivered to the remainder of the analyzers on a dry basis. 

Data Acquisition 

Concentration values were collected using a Baldwin Environmental RM Plus Parametrics 

data acquisition system. The data was recorded every fifteen-seconds and then averaged 

for each six,,second interval. Each minute average was then averaged for the duration of 

each test run. 

During all testing, the unit was operating within normal operating parameters; at a range 

appropriate in accordance with applicable permits. 
Entec Sewices, Inc 

t6 D Commerce Ave. HUe•rOWn, AL 35023 

STACK DRAWING & TRAVERSE POINT LOCATION 

Client: Beiden Brick Job No. 26t08 

SourcE: Bdck Plant Tunnel Kiln No. 2 input By: Tommy Lot• Jr. 

Type of Traverse Velocity (V) or Pa•culat• (P): • Port Ty• •1• Po• Oiame•t 2.0" 

S•ck Dl•etet, •nc•s: 57• •¢k At•, F•: 18.033 

S•ck H•tgh• • 6 HumOr • Po•: 2 

Stack Pm•: tnoh• Duct O•metem Leng• • P• Inch•: 7,• 

t 74•0 3,03 To=I Num•r of Tmveme P•n•: •2 Upstream Disturbance: 

Downstr_,_•__m D.L•.urbance: 

57.5 INCHES 

tI•CHES 

432.0 

FLOW 

Inelde •t•c;k Ou•I•l• Nipple 

Point No, inches Inches 

2,$ 

3 17.0 24.5 

Ft.ATA Probe 

9,8 17.3 

47.7 •5,2 

Adjusted points dtertmte¢ > 24" no point c|o•ter than 1,0 inch 

Adjusted pCnts dtanmtsr_< 24" no point closet t•an 0.5 Inch 

4 points per port if the 8 2 dlametem downstream and 

ul•tteam crfteda is met, 
Instrument Sampling Train 

00000 n 

NOx 

CO 

so• 

co= 

o= 

Caltbra•on 

Gases 
FT-IR Sampling Train 

Pro• 

Commun|catlon Lines 

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