P.O. Box 598 

Addison, TX 75001 

(972) 931-7127 

SOURCE EMISSIONS SURVEY 

OF 

BORAL BRICKS, INC. 

KILN SCRUBBER OUTLET STACK (EPN K) 

HENDERSON, TEXAS 

TCEQ PERMIT 21012 

MAY 2004 

FILE NUMBER 04-171 

certify that have personally checked and am familiar with the information 

submitted herein, and based on my inquiries of those individuals immediately 

responsible for obtaining the information, believe the submitted information is 

true, accurate, and complete. 

Senior Quality Assurance Manager 
•EAVIF•)AFFEATAL mEEQ 

TABLE OF CONTENTS 

INTRODUCTION 

SUMMARY OF RESULTS 

DISCUSSION OF RESULTS 

DESCRIPTION OF PROCESS 

DESCRIPTION OF SAMPLING LOCATION 

SAMPLING AND ANALYTICAL PROCEDURES 

DESCRIPTION OF TESTS 

APPENDICES 

A. Location of Sampling Points 

B. Source Emissions Calculations 

C. Calibration Data 

D. Field Testing Data 

E. Analytical Data 

F. Plant Operational Data 

G. TCEQ Permit 

H. Chain of Custody 

I. Resumes of Test Personne• 

PAGE 

1 

2 

5 

7 

9 

11 

16 

17 

04-1 71 
SOURCE EMISSIONS SURVEY 

BORAL BRICKS, INC. 

KILN SCRUBBER OUTLET STACK (EPN K) 

HENDERSON, TEXAS 

TCEQ PERMIT 21012 

INTRODUCTION 

METCO Environmental, P.O. Box 598, Addison, Texas, conducted a source emissions 

survey of Boral Bricks, Inc., located in Henderson, Texas, on May 24, 25, and 26, 2004. 

The purpose of these tests was to determine the concentrations of PM10 particulate 

matter and EPA Method 5 particulate matter being emitted to the atmosphere via the 

Kiln Scrubber Outlet Stack (EPN K), in order to comply with TCEQ Permit 21012. The 

testing was performed while the unit was operating at an average combined production 

rate The results demonstrated that the unit was in compliance 

with TCEQ Permit 21012. 

The sampling was performed by the following METCO personnel: Jason Brown Project 

Supervisor, Mark Glicer, Mitchell Stuckert, and Ryan Spicer. 

The sampling followed the procedures set forth in the Code of Federal Regulations, 

Title 40, Chapter I, Part 60, AppendixA, Method /- , and in the 

"Sampling Procedures Manual, Texas Air Control Board, Revised July 1985". 

04-171 -1- 
•EAVIFOArT•ATAL rrlEEQ 

SUMMARY OF RESULTS 

Kiln Scrubber Outlet Stack (EPN K) 

Front-Half Total 

PM 10 Particulate Matter PM 10 Particulate Matter 

Run Emissions Emissions 

Number ('.qr/dscf*) (Ibs/hr) (.qr/dscf*) (Ibs/hr) 

1 0.0067 2.36 0.0129 4.51 

2 0.0056 1.90 0.0188 6.39 

3 0.0071 2.37 0.0107 3.56 

4 0.0063 2.12 0.0137 4.64 

Average 0.0064 2.19 0.0140 4.78 

Allowable 

Emission Rate 20.63 

EPA Method 5 EPA Method 5 

Front Half Total 

Run 

P•articuiate 

Emissions 

Matter • 

Emissions 

Number (.clr/dscf*) (Ibs/hr) (.qr/dscf*) (Ibs/hr) 

2 0.0322 10.95 0.0336 11.46 

3 0.0254 8.47 0.0369 12.34 

4 0.0182 6.12 0.0273 9.20 

Average 0.0253 8.51 •_.__•__ lll• .-TI• 

* 29.92 "Hg, 68°F (760 mm Hg, 20°C) 

Note: Run Number 1 for EPA Method 5 particulate matter was invalid due to a 

broken probe liner. 

04-171 -2- 
SUMMARY OF RESULTS 

Kiln Scrubber Outlet Stack (EPN K) 

PM 10 Particulate Matter 

Run Number 2 

Date 05/25/04 05/25/04 05/25/04 05/25/04 

Time 0900-1019 1313-1444 1546-1702 1802-1918 

Stack Flow Rate ACFM 73,339 72,036 71,134 72,363 

40,737 39,748 38,853 39,388 

8.60 8.66 8.95 8.88 

2.2 2.2 2.0 

Stack Flow Rate DSCFM* 

% Water Vapor % Vol. 

% CO2 % Voi. 

% 02 % Vol. 

Excess Air @ Sampling Point % 

Stack Temperature _o F 397 

29.40 

15.8 

266.4 

Stack Pressure "Hg 

Percent Isokinetic 100.4 

Calculated Cut-Off Diameter microns 9.5 

0.0067 

grains/cf @ Stack Conditions 0.0037 

Ibs/hr 2.36 

Total Catch 

PM 10 Particulate Matter Emissions 

Filter Catch 

grains/dscf* 

grains/dscf* 0.0129 

grains/cf @ Stack Conditions 0.0071 

Ibs/hr 4.51 

2.2 

15.8 15.8 16.2 

266.4 266.4 295.8 

403 408 411 

29.43 29.40 29.38 

101.6 110.0 104.2 

9.6 9.2 9.5 

0.0056 0.0071 0.0063 

0.0031 0.0039 0.0034 

1.90 2.37 2.12 

0.0188 0.0107 

0.0103 0.0058 

6.39 3.56 

0.0137 

0.0075 

4.64 

29.92 "Hg, 68°F (760 mm Hg, 20°C) 

04-171 -3- 
SUMMARY OF RESULTS 

Kiln Scrubber Outlet Stack (EPN K) 

EPA Method 5••• 

Run Number 2 3 4 

Date 05/25/04 05/25/04 05/25/04 

Time 1313-1444 1546-1702 1802-1919 

Stack Flow Rate ACFM 72,023 71,083 72,389 

Stack Flow Rate DSCFM* 39,750 38,984 39,295 

% Water Vapor % Vol. 8.62 8.57 9.13 

% CO2 % Vol. 2.2 2.2 2.0 

% O2 % Vol. 15.8 15.8 16.2 

Stack Temperature _o F 403 408 411 

Stack Pressure -"Hg 29.43 29.40 29.38 

Percent Isokinetic 96.7 102.4 108.1 

Particulate Matter Emissions 

Probe & Filter Catch 

grains/dscf* 0.0322 0.0254 0.0182 

grains/cf @ Stack Conditions 0.0177 0.0139 0.0098 

Ibs/hr 10.95 8.47 6.12 

Total Catch 

grains/dscf* 0.0336 0.0369 0.0273 

grains/cf @ Stack Conditions 0.0185 0.0202 0.0148 

Ibs/hr 11.46 12.34 9.20 

29.92 "Hg, 68°F (760 mm Hg, 20°C) 

Note: Run Number 1 was invalid due to a broken probe liner. 

04-171 -4- 
DISCUSSION OF RESULTS 

The four tests for PM 10 particulate matter appeared to be valid representations of the 

actual emissions during the tests. All leak checks performed on the sampling train and 

the pitot tubes showed no leaks before or after each test. The indicative parameters 

calculated from the field data were in close agreement. The moisture percentages for 

the four tests were within 2.0 percent of the mean value. The measured flow rates (Qs) 

for the tests were within 2.7 percent of the mean value. The rates of sampling for the 

four tests were within the specified limits (80 to 120 percent isokinetic). The greatest 

deviation from 100 percent isokinetic was 10.0 percent. The calculated cut-off 

diameters were within the specified limits of 9.0 to 11.0 microns. 

The calculated emissions (pounds per hour) of total PM 10 particulate matter for the 

four tests showed a range of -25.4 percent to +33.8 percent variation from the mean 

value. 

Run Number 1 for EPA Method 5 particulate matter was invalid due to a broken probe 

liner. 

The three valid tests for EPA Method 5 particulate matter appeared to be accurate 

representations of the actual emissions during the tests. All leak checks performed on 

the sampling train and the pitot tubes showed no leaks before or after each test. The 

indicative parameters calculated from the field data were in close agreement. The 

moisture percentages for the three valid tests were within 4.1 percent of the mean 

value. The measured flow rates (Qs) for the tests were within 1.0 percent of the mean 

04-171 -5- 
value. The rates of sampling for the three tests were within the specified limits (90 to 

110 percent isokinetic). The greatest deviation from 100 percent isokinetic was 

8.1 percent. 

The calculated emissions (pounds per hour) of total EPA Method 5 particulate matter 

for the three valid tests showed a range of -16.4 percent to +12.2 percent variation from 

the mean value. 

04-171 -6- 
DESCRIPTION OF PROCESS 

The kilns are used to fire the green bricks after they come out of the brick machines in 

the brick manufacturing area. The green bricks are placed on kiln cars and taken to the 

kiln area. There are two (2) tunnel kilns. Kiln No. 1 (FIN K1) and Kiln No. 2 (FIN K2) 

used to fire the bricks. Each tunnel kiln has its own preheat areas and two dryers 

located prior to the tunnel kiln. 

The preheat areas are designated as Kiln 1 Preheat Area (FIN PHA1) and Kiln 2 

Preheat Area (FIN PHA2). In the preheat area, the bricks are heated using air from the 

cooling zone of the kiin. There are no auxiliary heating units used in the preheat areas. 

The exhausts from the preheat areas are vented to the dryers. After preheating, the 

bricks are placed into one of two dryers located upstream of each kiln. 

The dryers for Kiln No. 1 are designated as Dryer No. 1A (FIN KID1) and Dryer No. 1B 

(FIN KID2). The dryers for Kiln No. 2 are designated as Dryer No. 2A (FIN K2D1) and 

Dryer No. 2B (FIN K2D2). The dryers are heated with the air from the cooling zones of 

the kilns. No auxiliary heating units are used on the dryers. The exhaust from the 

dryers vent directly to the atmosphere, with each dryer having its own exhaust stack. 

The exhaust stacks from the Kiln No. 1 dryers are designated as Dryer 1A Stack (FIN 

KID1) and Dryer 1B Stack (EPN KID2). 

From the dryers, the bricks will move through the tunnel kiln on kiln cars. The kilns are 

heated using natural gas. Each kiln has two exhausts: the firing zone exhaust and the 

cooling zone exhaust. The firing zone exhaust contains the products of combustion 

from the burning of natural gas and off gases from the firing of the bricks. The cooling 

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mErEQ 

DESCRIPTION OF TESTS 

Personnel from METCO Environmental arrived at the plant at 1:00 p.m. on Monday, 

May 24, 2004. After meeting with plant personnel, the equipment was moved onto the 

Kiln Scrubber Outlet Stack (EPN K). The equipment was prepared for testing and the 

preliminary data was collected. The equipment was secured for the night and all work 

was completed at 6:45 p.m. 

On Tuesday, May 25, work began at 7:15 a.m. The equipment was prepared for 

testing. The first set of tests for PM 10 particulate matter and EPA Method 5 

particulate matter began at 9:00 a.m. and was completed at 10:19 a.m. Run Number 1 

for EPA Method 5 particulate matter was invalid due to a broken probe liner. The 

second set of tests began at 1:13 p.m. Testing continued until completion of the fourth 

set of tests at 7:19 p.m. The samples were recovered. The equipment was secured for 

the night and all work was completed at 9:00 p.m. 

On Wednesday, May 26, work began at 8:00 a.m. The equipment was moved off of the 

stack and loaded into the sampling van. The samples were transported to METCO 

Environmental's laboratory in Dallas, Texas, for analysis and evaluation. 

Operations at Boral Bricks, Inc., Kiln Scrubber Outlet Stack (EPN K), located in 

Henderson, Texas, were completed at 9:00 a.m. on Wednesday, May 26, 2004. 

04-171 -16-