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

ManagermEEQ•EAVIF•)AFFEATAL

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• PAGE12579111617

04-1 71SOURCE 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-rrlEEQ•EAVIFOArT•ATAL

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 P•articuiate Matter • Run Emissions 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 39729.4015.8266.4

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 Catchgrains/dscf*

grains/dscf* 0.0129 grains/cf @ Stack Conditions 0.0071 Ibs/hr 4.51 2.215.8 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

0.01370.00754.64

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 Catchgrains/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

04-171 -7-04-171 LLI 0"•

a. -]4-04-171 E

III "1

-15- oEmErEQ

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-