# TEST REPORT for 

# Hanson Brick Pleasant Garden, NC

Hanson Brick East, LLC dba Hanson Brick 1410 Forest Acres Circle P. O. Box 368 Pleasant Garden, NC 27313


## Pre ared b : 

# AIR 

# / TECH
Air-Tech Environmental, LLC P. O. Box 12353 Research Triangle Park, NC 27709-2353

(919) 544-6338
June 5, 2006

### Air-Tech Environmental, LLC Hanson Brick/PG Test Report (AT06-0396-HSC) June 5, 2006 - P a e ii 

## Air-Tech Environmental, LLC Report Certification This report has been reviewed by the following Air-Tech Environmental, LLC personnel and is a true representation of the results obtained from the sampling program Brick Kiln (ID #ES8-LK2) and the dry limestone adsorber (DLA) (ID #CD-ES8LK2) at the Hanson Brick facility in Pleasant Garden, NC. The sampling and analytical methods were performed in accordance with procedures approved by the State of North Carolina.

Team Leader: Michael W. Hartman, Principal Scientist Date
Reviewer: Darrell H. Doerle, Senior Staff Scientist Date

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# TABLE OF CONTENTS Page


## 1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2.0 RESULTS SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2.1 HF and HCI Sampling Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2.2 Particulate Matter Sampling Results . . . . : . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3.0 SAMPLING AND ANALYTICAL METHODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4.0 QUALITY ASSURANCE/ QUALITY CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Tables 

## Table 1. Hf and HCI Results Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Table 2. Method 5/202 Results Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Table 3. QASummary ..................................................10
Figures


## Figure 1 Process Schematic, Hanson Brick (Pleasant Garden) . . . . . . . . . . . . . . . . . . . . 7 Figure 2 Method 26A Sampling Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Appendices Appendix A Field Data Sheets and Run Summaries Appendix B Analytical Report Appendix C Meter Calibrations

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# 1.0 INTRODUCTION On May 10, 2006, Air-Tech Environmental 

## perFormed sampling at the Hanson Brick Pleasant Garden facility in order to demonstrate compliance with Air Permit No. 05806R10. Emissions testing was conducted to characterize emissions at brick kiln ID No. ES8-LK2. This kiln exhausts to a dry lime absorber (DLA), ID No. CD-ES8LK2, for control of hydrogen fluoride (HF) emissions. Sampling was conducted at the exhaust stack of the DLA to characterize emissions of HF, hydrogen chloride (HCI), and particulate matter (PM) utilizing the sampling procedures of Method 26A. Additionally, Method 26 samples were collected at the inlet to the DLA in order to determine the DLA removal efficiency for HF and HCI. A summary of the results is presented in the table below.
This report presents the results of the sampling in Section 2. A description of the sampling locations and the methodologies employed in emissions characterizations are contained in Section 3. Section 4 presents an assessment of the quality control measures taken during the performance of this test program.
Mass Rate (Ib/hr) DRE 

## (%) Inlet Outlet PM 

## NM a 

## 0.33 NM H F 3.66 0.008 99.8 HCI 1 

## 1.12 1.08 3.2

a 

## NM = not measured

### Air-Tech Environmental, LLC Hanson Brick/PG Test Report (aT06-0396-HBC) June 5, 2006 - Page 2 

# 2.0 RESULTS SUMMARY Three test runs were conducted for the determination of emission rates for each of the compounds of interest. Detailed test summaries grouped by test method are presented below. Efforts were made, successfully, to collect all samples during production of a single type of product. The brick production rate during the testing averaged 12.7 tons per hour. Pressure drop across the DLA averaged 0.29 "H 2 0 (during times without flashing) for the test periods. 2.1 HF and HC/ Sampling Results Samples were collected at the DLA inlet and exhaust for all three test runs. DLA inlet samples were collected simulaneously with the outlet samples. A summary of the results of the HF and HCI flue gas concentrations and emission rates is presented in Table 1. AII tests did comply with field sampling procedures pertaining to sample train operating temperatures and leak checks. Flue gas concentrations of HF were found to average 58.7 ppm at the DLA inlet and less than 0.12 ppm at the outlet. These concentrations yield mass rates of HF that average 3.66 Ib/hr into the DLA and less than 0.008 Ib/hr out. These measurements show a removal efficiency exceeding 99.8% for HF. Flue gas concentrations and mass rates of HCI were nearly the same into and out of the DLA. The second test shows a greater amount of HCI being exhausted than entering the DLA. None of these measurements indicate great amounts of HCI present in the flue gas. Average concentrations were found to be less than 10 ppm yielding a mass rate of just more than 1 Ib/hr.

### Air-Tech Environmental, LLC Hanson Brick/PG Test Report (AT06-0396-Hac)



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## Table 1. HF and HCI Results Summary

F/ue Gas Concentration Mass Rate 

### Flow (dscfm) HF 

### (ppm) HCI 

### (ppm) HF 

### (Ib/hr) HCI (Ib/hr) DRE 

### (%) 

# L:Izj Ib/ton Ib/ton Run # 

### Time Inlet Outlet In/et Outlet 

### In/et Outlet brick 

### Inlet Outlet brick HF HCI 1 1042- 1148 19539 19186 57.6 0.10 8.7 8.0 3.50 0.006 0.0005 0.97 0.89 0.070 99.8 8.7 2 1224- 1328 20460 20227 59.0 0.14 9.4 10.8 3.76 0.009 0.0007 1.11 1.26 0.099 99.8 13.1 3 1356- 1501 20125 19331 59.5 0.13 11.0 9.8 3.73 0.008 0.0006 1.27 1.09 0.086 99.8 1.42 Avera e 20041 19581 58.7 0.12 9.7 

## T 9.67 3.66 0.008 0.0006 

# 1 1.12 

# 1 1.08 

# 1 0.085 99.8 3.2 

## 2.2 Particulate Sampling Resu/ts Particulate sampling was performed for the determination of filterable PM using procedures of Method 5. These results are presented in Table 2. The average concentration of PM was found to be 0.0020 grains per dry standard cubic foot (gr/dscf), ranging from 0.0015 to 0.0024 gr/dscf. These low concentrations yield emission rates that range from 0.25 to 0.40 Ib/hr, and average 0.33 Ib/hr.



## Table 2. Method 5/202 Results Summary

Run # 

### Time Concentration r/dsc Flow

dscfm Emission

Rate 

### #/hr Emission Rate



### Ib/ton brick 1 

### 1042-1148 0.0021 19186 0.35 0.028 2 1224-1328 0.0015 20227 0.25 0.020 3 1356-1501 0.0024 19331 0.40 0.032 Avera e 

# 1 0.0020 19581 0.33 0.026

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# 3.0 SAMPLING AND ANALYTICAL METHODS The samples were collected from the exhaust of the brick kiln, a natural gas fired process operating continuously 24 hours per day, seven days per week. There was no PM control of emissions from this source; acid gases were scrubbed in a dry lime absorber prior to exhaust. A schematic of the process exhaust is contained in Figure 1. Inlet samples were collected from a circular duct 58 inches in diameter. Two sampling ports, placed at right angles, provided for access for velocity traverses. These ports were in a straight run of duct easily meeting the 8 and 2 requirements of Method 1. A total of 12 points were sampled for velocity measurements. A schematic of this test location showing sample point location on the "Traverse Point Location Form" has been appended with the test data. DLA outlet sampling was conducted at the exhaust stack. This sampling location also met the requirements of Method 1 allowing a 12 point test to be conducted. A schematic of this location on the "Traverse Point Location Form" showing point placement has been appended as well. Sampling was performed according to the procedures of Method 26A at the outlet test location. Non-isokinetic Method 26 samples were collected from three points at the inlet location. Three one hour samples were collected simultaneously at each sampling location. Concurrent with the testing readings of DLA pressure drop were made at the facility monitor, a photohelic difFerential pressure gauge. These readings were taken manually at approximately 15 minute intervals. An actual calibration of the facility monitor was not attempted. . The outlet sampling was conducted according to the procedures of EPA Method 26A. These procedures entail isokinetic collection of a particulate sample followed by collection of acid gases in dilute solutions of sulfuric acid. A schematic of this sampling train is contained in Figure 2. Note that the caustic impingers used for the collection of diatomic halogens was not used. The non-isokinetic Method 26 train employed at the DLA inlet was charged in identical fashion. The flue gas sample was collected through a glass nozzle into a glass probe. Particulate matter was filtered through a heated teflon fliter and then entered the impinger portion of the sampling train. This impinger portion consisted of two impingers containing 100 ml of 0.1 N sulfuric acid each followed by an empty impinger, then a silica gel containing impinger used for final moisture collection. A type S pitot tube and

### Air-Tech Environmental, LLC Hanson Brick/PG Test Report (ATOS-OSSS-HBC) June 5, 2006 - Page 5 

## thermocouple were used to measure velocity pressures and temperatures at each sampling point. A calibrated dry gas meter was used to measure sample volume. A calibrated orifice placed on the meter outlet was used to set sample rate. With the exception of collection of a particulate fraction at the DLA inlet, sample recovery resulted in the collection of the following sample fractions. • Acetone washes, with brushing, of those portions of the sample train upstream of the filter. • The filter. • The sulfuric acid impinger solutions and water rinses of all exposed glass surfaces downstream from the filter to the inlet to the silica gel impinger. • The silica gel. Acetone washes were dried down in tared beakers for the gravimetric determination of weight gain. This gain, added to that determined for the tared filters, made up the particulate total of the sample. The total mass of PM collected was divided by the sample volume to determine particulate concentration (gr/dscf). This value was multiplied by flue gas flow rate to determine mass emission rate (Ib/hr). Mass emissions were divided by production rates to determine emissions in terms of brick production rates (Ib/ton). Complete example calculations as well as the analytical and run data have been appended. The acid matrix samples were analyzed for fluoride and chloride ions following the ion chromatography analytical procedures of Method 26A. These analyses yielded liquid concentrations for the ions of interest (ug/ml). Conversions of ion concentration to acid concentration were made on a one to one basis. These acid concentrations were then converted to total mass of the compound of interest collected using the liquid sample volume. This total mass was then converted to mass rates for each sampling location in fashion similar to the particulate matter calculations. DLA removal efficiencies were calculated based on the calculated mass rates of the compounds of interest at the inlet and outlet. Complete analytical summaries and example calculations have been appended. After noting the post test weight gain, the silica gel was discarded. This weight gain was added to that determined for the rest of the impinger train prior to sample recovery. The total weight gain of the impinger train was attributed to flue gas water vapor and used for flue gas moisture fraction calculations (Method 4). Flue gas fixed gas analysis

### Air-Tech Environmental, LLC Hanson Brick/PG Test Report (AT06-0396-HSC) June 5, 2006 - Pa e 6 

## was performed on bags collected during each test using the grab procedures of Method 3 using an Orsat combustion analyzer. These data, along with the velocity pressure and temperature (Method 2) determined each sample point (Method 1) during the performance of the isokinetic sampling were used to calculate flue gas volumetric flow rates used in mass rate calculations.

### Air-Tech Environmental, LLC Hanson Brick/PG Test Report (nT06-0396-HBC) June 5, 2006 - Page 7

f— 5 ' — ~



## Figure 1. Process Schematic, Hanson Brick (Pleasant Garden)I ',' ceBath I,; I I I IIl I 

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e 

# O Type S Pitot Tube

Sensors
Orifice

Dry Gas Meter 

### Air-Tech Environmental, LLC Hanson Brick/PG Test Report (AT06-0396-HBC) June 5, 2006 - Pag e 8

Temperature Sensor

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## Figure 2. Method 26A Sampling Train

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# 4.0 QUALITY ASSURANCE / QUALITY CONTROL The Quality Assurance (QA) procedures required by the reference methodologies employed during the testing were strictly adhered to during the performance of this test program. Such adherence ensures production of useful and valid data throughout the course of the project. An analytical audit was not provided to Air-Tech for analysis, therefore the measures made as described below comprise the analytical QA. Control criteria for these measures are not specified in the method. The QA procedures described in this section represent an integral part of the overall sampling and analytical scheme. The acceptance criteria, control limits, and the results of these measures obtained during this testing and analysis are summarized in Table 4. A brief discussion of the QA measures is presented below. QA measures taken to provide some assessment of the quality of sample collection included measures of sampling rate, and the assessment of the accuracy of inetered gas volumes and the integrity of sampling train. Outlet sampling rates, assessed as % isokinetics, met method criteria for all test runs. Therefore, any sample bias caused by non representative collection of differing particle sizes (either particulate matter or water droplets) was within acceptable limits. Though the dry gas meters used for sample volume determination meet method criteria for accuracy, the outlet gas meter does not meet accuracy criteria without application of the meter correction factor. Post-test sample train leak checks meet the method criteria for all test runs. The analytical measures of QA meet the method criteria for acetone purity, an assessment of the Method 5 analysis. The Method 26A analytical QC relies on performance of an audit to be provided at the NCDENR discretion. In absence of such a sample the analytical QA assessment was made based on the measurements tabulated in Table 4. These data show that the analysis suffered no significant bias due to the reagents or the sample matrix. AII duplicate analysis show a precision of measurement of exceeding 2% of the reported value for all measurements. The calibration linearity indicates the results will be accurate regardless of where they fall on the calibration curve.

### Air-Tech Environmental, LLC Hanson Brick/PG Test Report (,aT06-0396-HSC)

June 5, 2006 - Pa e 10 

## Table 4. QA Summary
Criteria Contro/ 

### Limit Result Sampling 

### % Isokinetics 100 ± 10% Inlet NA Outlet 98 - 99% Dry Gas Meter Calibration (M26) 1.00 ± 2% Inlet 0.9968 Outlet 1.0209 Post Test Calibration Check (M26A) y d 

### ± 5% Inlet 1.0191 Outlet 1.0505 Sample Train Leak Rate (M26A) <0.02 cfm Inlet 0.00 - 0.00 Outlet 0.00 - 0.00 Analytical 

### Acetone Blank (M5) < 0.001 wt % 0.00OOg/788 1-12SO4 Field Blank (M26A) 1-12SO4 Lab Blank (M26A) Lab Water Blank (M26A) Measure and record results HF ND HCI ND
Matrix Spike Recovery Not specified HF 97.2% Not specified HCI 112% Duplicate Analysis, Inlet ± 5% mean HF 0.0 - 0.9% t 5% mean HCI 0.0 - 1.2% Duplicate Analysis, Outlet ± 5% mean HF 0.1 - 1.3% ± 5% mean HCI 0.8 - 1.3% Calibration Linearity Not specified HF R Z = 0.9997 Not s ecified HCI R 2 = 0.9998

# Appendix A Field Data Sheets and Run SummariesR m N O N ~ N N O M C M N lo: M O O O O O

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## Facility: Hanson Brick

Date: 05/10/2006 Location: Outlet Run Number: 1 Sam le T e: M5/HCI Start Time: End Time: Initial Leak Check: Final Leak Check: 1042 1148 0.000@10" 0.000@3" Total Sampling Time (min) 60.0 Corrected Barometric Pressure (in Hg) 29.05 Absolute Stack Pressure (in Hg) 29.04 Stack Static Pressure (in H20) -0.15 Average Stack Temperature (°F) 244.42 Stack Area (sq in) 2642.08 Actual Meter Volume (cu ft) 33.458 Average Meter Pressure (in H20) 1.12 Average Meter Temperature (°F) 69.50 Moisture Collected (g) 71.80 Carbon Dioxide Concentration (%V) 0.0 Oxygen Concentration (%V) 20.9 Nitrogen Concentration (%V) 79.1 Dry Gas Meter Factor 1.0210 Nozzle Diameter (in) 0.312 Pitot Constant 0.84 Average Sampling Rate (dscfm) 0.553 Standard Metered Volume (dscf) 33.179 Standard Metered Volume (dscm) 0.940 Stack Moisture (%V) 9.24 Mole Fraction Dry Stack Gas 0.908 Dry Molecular Weight 28.84 W 

## e t Mol 

## ec ular Weight 27.83 Stack Gas Veloca y pm Stack Gas Velocity (mpm) 482.82 Volumetric Flow Rate (acfm) 29064.15 Volumetric Flow Rate (acmm) 823.10 Volumetric Flow Rate (dscfm) 19185.98 Volumetric Flow Rate (dscmm) 543.35 Percent Isokinetic 99.60 Percent Excess Air -1174157.30 Concentration (g/dscm) 0.00 Concentration (kg/hr) 0.00 Concentration (ppmv) 0.00 Emissions Ib/hr 0.00

## Facility: Hanson Brick

Date: 05/10/2006 Location: Outlet Run Number: 2 Sam le T e: M5/HCI Start Time: End Time: Initial Leak Check: Final Leak Check: 

## 1224 1328 0.000@10" 0.000@4" Total Sampling Time (min) 60.0 Corrected Barometric Pressure (in Hg) 29.05 Absolute Stack Pressure (in Hg) 29.04 Stack Static Pressure (in H20) -0.15 Average Stack Temperature (°F) 246.08 Stack Area (sq in) 2642.08 Actual Meter Volume (cu ft) 34.316 Average Meter Pressure (in H20) 1.18 Average Meter Temperature (°F) 71.92 Moisture Collected (g) 66.80 Carbon Dioxide Concentration (%V) 0.0 Oxygen Concentration (%V) 20.9 Nitrogen Concentration (%V) 79.1 Dry Gas Meter Factor 1.0210 Nozzle Diameter (in) 0.312 Pitot Constant 0.84 Average Sampling Rate (dscfm) 0.565 Standard Metered Volume (dscf) 33.872 Standard Metered Volume (dscm) 0.959 Stack Moisture (%V) 8.49 Mole Fraction Dry Stack Gas 0.915 Dry Molecular Weight 28.84 Wet Molecular Weight 27.92 Stack Gas Velocity (fpm) 1660.22 Stack Gas Velocity (mpm) 506.04 Volumetric Flow Rate (acfm) 30461.40 Volumetric Flow Rate (acmm) 862.67 Volumetric Flow Rate (dscfm) 20226.63 Volumetric Flow Rate (dscmm) 572.82 Percent Isokinetic 96.45 Percent Excess Air -1174157.30 Concentration (g/dscm) 0.00 Concentration (kg/hr) 0.00 Concentration (ppmv) 0.00 Emissions Ib/hr 0.00

## Facility: Hanson Brick

Date: 05/10/2006 Location: Outlet Run Number: 3 Sam le T e: M5/HCI Start Time: End Time: Initial Leak Check: Final Leak Check: 1356 1501 0.000@10" 0.000@3" Total Sampling Time (min) 60.0 Corrected Barometric Pressure (in Hg) 29.05 Absolute Stack Pressure (in Hg) 29.04 Stack Static Pressure (in H20) -0.15 Average Stack Temperature (°F) 258.67 Stack Area (sq in) 2642.08 Actual Meter Volume (cu ft) 32.555 Average Meter Pressure (in H20) 1.07 Average Meter Temperature (°F) 74.92 Moisture Collected (g) 66.80 Carbon Dioxide Concentration (%V) 0.0 Oxygen Concentration (%V) 20.9 Nitrogen Concentration (%V) 79.1 Dry Gas Meter Factor 1.0210 Nozzle Diameter (in) 0.312 Pitot Constant 0.84 Average Sampling Rate (dscfm) 0.532 Standard Metered Volume (dscf) 31.948 Standard Metered Volume (dscm) 0.905 Stack Moisture (%V) 8.96 Mole Fraction Dry Stack Gas 0.910 Dry Molecular Weight 28.84 Wet Molecular Weight 27.87 Stack Gas Velocity (fpm) 1623.26 Stack Gas Velocity (mpm) 494.77 Volumetric Flow Rate (acfm) 29783.25 Volumetric Flow Rate (acmm) 843.46 Volumetric Flow Rate (dscfm) 19331.02 Volumetric Flow Rate (dscmm) 547.45 Percent Isokinetic 95.19 Percent Excess Air -1174157.30 Concentration (g/dscm) 0.00 Concentration (kg/hr) 0.00 Concentration (ppmv) 0.00 Emissions Ib/hr 0.00V 7

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## All Angles >20 0 Require Alignment Approach Sampling.

## Facility: Hanson Brick

Date: 05/10/2006 Location: Inlet Run Number: 1 Sam le T e: Velocit Start Time: End Time: Initial Leak Check: Final Leak Check: 1042 1142 0.0001@10" 0.00@6" Total Sampling Time (min) 60.0 Corrected Barometric Pressure (in Hg) 29.13 Absolute Stack Pressure (in Hg) 29.12 Stack Static Pressure (in H20) -0.20 Average Stack Temperature (°F) 251.17 Stack Area (sq in) 2642.08 Actual Meter Volume (cu ft) 44.732 Average Meter Pressure (in H20) 1.80 Average Meter Temperature (°F) 74.21 Moisture Collected (g) 79.00 Carbon Dioxide Concentration (%V) 0.0 Oxygen Concentration (%V) 0.0 Nitrogen Concentration (%V) 100.0 Dry Gas Meter Factor 0.9968 Nozzle Diameter (in) NA Pitot Constant 0.84 Average Sampling Rate (dscfm) 0.718 Standard Metered Volume (dscf) 43.108 Standard Metered Volume (dscm) 1.221 Stack Moisture (%V) 7.94 Mole Fraction Dry Stack Gas 0.921 Dry Molecular Weight 28.00 Wet Molecular Weight 27.21 Stack Gas Velocity (fpm) 1601.07 Stack Gas Velocity (mpm) 488.01 Volumetric Flow Rate (acfm) 29376.07 Volumetric Flow Rate (acmm) 831.93 Volumetric Flow Rate (dscfm) 19538.54 Volumetric Flow Rate (dscmm) 553.33 Percent Isokinetic ERR Percent Excess Air 0.00 Concentration (g/dscm) 0.00 Concentration (kg/hr) 0.00 Concentration (ppmv) 0.00 Emissions Ib/hr 0.00 ;~ `

## Facility: Hanson Brick

Date: 05/10/2006 Location: Inlet Run Number: 2 Sam le T e: Velocit Start Time: End Time: Initial Leak Check: Final Leak Check: 1224 1324 0.000@8" 0.000@8" Total Sampling Time (min) 60.0 Corrected Barometric Pressure (in Hg) 29.08 Absolute Stack Pressure (in Hg) 29.07 Stack Static Pressure (in H20) -0.20 Average Stack Temperature (°F) 255.75 Stack Area (sq in) 2642.08 Actual Meter Volume (cu ft) 44.526 Average Meter Pressure (in H20) 1.80 Average Meter Temperature (°F) 74.21 Moisture Collected (g) 82.30 Carbon Dioxide Concentration (%V) 0.0 Oxygen Concentration (%V) 0.0 Nitrogen Concentration (%V) 100.0 Dry Gas Meter Factor 0.9968 Nozzle Diameter (in) NA Pitot Constant 0.84 Average Sampling Rate (dscfm) 0.714 Standard Metered Volume (dscf) 42.838 Standard Metered Volume (dscm) 1.213 Stack Moisture (%V) 8.29 Mole Fraction Dry Stack Gas 0.917 Dry Molecular Weight 28.00 Wet Molecular Weight 27.17 Stack Gas Velocity (fpm) 1696.74 Stack Gas Velocity (mpm) 517.17 Volumetric Flow Rate (acfm) 31131.37 Volumetric Flow Rate (acmm) 881.64 Volumetric Flow Rate (dscfm) 20459.54 Volumetric Flow Rate (dscmm) 579.41 Percent Isokinetic ERR Percent Excess Air 0.00 Concentration (g/dscm) 0.00 Concentration (kg/hr) 0.00 Concentration (ppmv) 0.00 Emissions Ib/hr 0.00

## Facility: Hanson Brick

Date: 05/10/2006 Location: Inlet Run Number: 3 Sam le T e: Veloci ty Start Time: End Time: Initial Leak Check: Final Leak Check: 1356 1456 0.000@10" 0.000@8" Total Sampling Time (min) 60.0 Corrected Barometric Pressure (in Hg) 29.08 Absolute Stack Pressure (in Hg) 29.07 Stack Static Pressure (in H20) -0.20 Average Stack Temperature (°F) 269.58 Stack Area (sq in) 2642.08 Actual Meter Volume (cu ft) 44.477 Average Meter Pressure (in H20) 1.80 Average Meter Temperature (°F) 77.75 Moisture Collected (g) 88.10 Carbon Dioxide Concentration (%V) 0.0 Oxygen Concentration (%V) 0.0 Nitrogen Concentration (%V) 100.0 Dry Gas Meter Factor 0.9968 Nozzle Diameter (in) NA Pitot Constant 0.84 Average Sampling Rate (dscfm) 0.708 Standard Metered Volume (dscf) 42.508 Standard Metered Volume (dscm) 1.204 Stack Moisture (%V) 8.89 Mole Fraction Dry Stack Gas 0.911 Dry Molecular Weight 28.00 Wet Molecular Weight 27.11 Stack Gas Velocity (fpm) 1712.39 Stack Gas Velocity (mpm) 521.94 Volumetric Flow Rate (acfm) 31418.46 Volumetric Flow Rate (acmm) 889.77 Volumetric Flow Rate (dscfm) 20125.15 Volumetric Flow Rate (dscmm) 569.94 Percent Isokinetic ERR Percent Excess Air 0.00 Concentration (g/dscm) 0.00 Concentration (kg/hr) 0.00 Concentration (ppmv) 0.00 Emissions Ib/hr 0.00

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## To: DH Doerle

From: Jack Garvey Subject: Stack Test Fired Brick Production Rate During each of three stack tests conducted on May 10, 2006, the kiln was operating on a 24 car kiln schedule. The average brick weight was 3.61bs per brick (SBE). The tons per hour is calculated as shown below: (24 cars/day) x(7056 SBEs per car) x(3.61bs per SBE) =12.70 tons/hour (24 hours per day) x(20001bs per ton))R~S~ ~,•~'I



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# ~

# Appendix B

Analytical Report

# Air-Tech Environmental, LLC 3216 S. Alston Ave. Durham, NC 27713



# Hanson Brick — Pleasant Garden
Analytical Report (0506-56)



# EPA Method 2" Hydrogen chloride Hyrdrogen fluoride

~ 

# Enthalpy Analytical, Inc.
~ Phone: (919) 850 - 4392 / Fax: (919) 850 - 9012 / www.enthalpy.com

t 

### 2202 Ellis Road Durham, NC 27703 - 5518

## I certify that to the best of my knowledge all analytical data presented in this report:

• Have been checked for completeness • Are accurate, error-free, and legible • Have been conducted in accordance with approved protocol, and that all deviations and analytical problems are summarized in the appropriate narrative(s) • This analytical report was prepared in Portable Document Format (.PDF) and contains 86 pages.

- 

# Rtc1jjh t

~ 

# . N~~ 

### QA Review Performed b y: Michle H. Bo yer

# Summary of Results

~

## Company Air-Tech Environmental Client # Hanson Brick

Analyst Initials KAM Job # 0506-56 Parameters EPA Method 26A PO # Verbal # Samples 6 runs & 1 blank Report Date 5/26/2006


# Com ound Sam le ID / 

# Catch Wei ht u
R1 In R2 In R3 In Hydrogen fluoride 58,432 59,525 59,516 Hydrogen chloride 16,235 17,609 20,347
R1 Out R2 Out R3 Out Hydrogen fluoride 77.3 J 115 99.0 Hydrogen chloride 11,624 15,933 13,661
Blank Hydrogen fluoride 31.1 ND Hydrogen chloride 41.8 ND

0506-56 Results 5/30/2006

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# Narrative Summary

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# ~

# Enthalpy Analytical Narrative Summary

Company.: Air-Tech Environmental, LLC Clierit;#; Hanson Brick

- 

## Pleasant Garden PO #: 

## Verbal Erithalpy; #: 0506- 56 :Analyst:. KAM 

# Parameters:. EPA Method 26A Custody Chris Todd of Enthalpy Analytical, Inc. received tie samples at

20.6 °C on 5/15/06 after being relinquished by Air-Tech Environmental, LLC. Prior to analysis the samples were kept under lock with access only by authorized personnel of Enthalpy Analytical, Inc. Analysis The samples were analyzed according to the procedures outlined in

EPA Method 26A. The acid (H2SO4) matrix samples were analyzed for the chloride (CI) and fluoride (F") ion. Quantitation was performed using a Hewlett Packard series 1100 High Performance Liquid Chromatograph equipped with a Dionex ED40 Electrochemical detector and a Dionex ASRS-ULTRA® 4-mm autosuppressor. Separation Separation was accomplished by Dionex IonPac AS-14A 4 mrn x

250 mm columns. A copy of the analytical method (COLSWTCFLM) is included. Before and after sample analysis, calibration curves were prepared and analyzed. The following table shows approximate retention times for each analyte. Analyte Retention Time (minutes) Fluoride (H 2 SO 4 ma.trix) 2.5 Chloride (H2SO4 matrix) 3.4 Matrix Spikes A 0.500-mL aliquot of a 100-fold diluted sample Run I Inlet was

spiked with 0.663 μg of hydrogen fluoride (HF) using 25.0 μL of a solution containing 26.5 μg/mL HF. The spiked sample was analyzed in the same manner as the other samples. The calculated HF spike recovery was 97.2%. A 0.500-mL aliquot of a 10-fold diluted sample Run 1 Inlet was spiked with 1.29 μg of hydrogen chloride (HCl) using 25.0 μL of a solution containing 51.4 μg/mL HCI. The spiked sample was analyzed in the same manner as the other samples. The calculated HCl spike recovery was 112%. Blanks One blank sample, Blank, was analyzed and reported. No blank

adjustments were made to any of the reported data. 

# Reproducibility OK

## Enthalpy Analytical Narrative Summary (continued) 

# Reporting Notes The HSO4 matrix samples were analyzed for F - and Cr but are

reported as HF and HC1 The peaks listed in the "Sample Chromatograms" section are labeled hydrogen fluoride and hydrogen chloride. The additional molecular weight contribution from the 9 is included in the results listed on each chromatogram and throughout the report. The instrument was set up using two columns of the same type to reduce the total time needed to run all the samples. Each sample was analyzed with two injections, one injection on each of the columns. Because the two injections were not on the same column, the retention times varied slightly more than our internal criteria of 3%. However the chloride response was similar on the two columns (as can be seen in the passing calibration curve), so the sample concentrations are accurate.

# General Reporting Notes

The following are general reporting notes that are applicable to all Enthalpy Analytical, Inc. reports, unless specifically noted otherwise. • The symbol MDL 

## represents the Minimum Detection Limit. Below this value the laboratory cannot confim the presence of the analyte of interest reliably. • The symbol LOQ 

## represents the Limit of Quantification. Below this value the laboratory cannot quantitate the analyte of interest within the criteria of the method. • The symbol ND 

## following a value indicates a non-detect or analytical result below the MDL. • The symbol J following a value indicates an analytical result between the MDL and the LOQ. A J flag indicates that the laboratory can positively identify the analyte of interest as present, but the value should be considered an estimate. • The symbol E following a value indicates an analytical result exceeding 100% of the highest calibration point • The symbol DF 

## represents a Dilution Factor. This number represents dilutions during the extraction and/or laboratory stages of sample treatment. The analytical result taken from a laboratory instrument is multiplied by the DF to get final results. • The Sample ID MS 

## represents a Matrix Spike. An aliquot of an actual sample is spiked with a known amount of analyte so that a percent recovery value can be determined. This shows what effect the sample matrix may have on the target analyte, i.e. whether or not anything in the sample matrix prohibits analysis for the analyte(s). • The Sample ID MSD 

## represents a Matrix Spike Duplicate. Prepared in the same manner as an MS, the use of duplicate matrix spikes allows further confirmation of laboratory quality by showing the consistency of results gained by performing the same steps multiple times. Most methods performed by Enthalpy do not require analysis of an MSD. • The Sample ID BS 

## represents a Blind Spike. A member of the Quality Assurance deparhnent has created BS samples for many of the analytes Enthalpy tests for, and only QA and the Enthalpy Analytical ownership have access to the actual values of these samples. The laboratory analyzes them without knowledge of the actual value, and the spreadsheets get completed for these samples solely by the QA group. • The Sample ID LCS 

## represents a Laboratory Control Sample. Whenever spikes are prepared for our clients more spikes are prepared than needed. The extras (randomly chosen) are kept in-house at the appropriate temperature conditions. When the spike samples come back from the client for analysis, the LCSs (usually two are saved) are analyzed to confirm that the analyte could be recovered from the media, separate from the spike samples which were used on the project and which may have had issues caused during collection and/or transport. • Significant Figures: Where the reported value is much greater than unity (1.00) in the units expressed (specifically values of 1,000 or greater), the number is rounded to a whole number of units, rather than to 3 significant figures. For example, a value of 10,456.45 ug catch is rounded to 10,456 ug. There are five significant digits reported, but no confidence should be placed on more than three significant digits.



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