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 - Pa 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 
Air-Tech Environmental, LLC 

Hanson Brick/PG Test Report (aTOS-OSSS-HBC) 

June 5, 2006 - Page iii 

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 
Air-Tech Environmental, LLC 

Hanson Brick/PG Test Report (AT06-0396-r,BC) 

June 5,2006 -Pa e 1 

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) 

June 5, 2006 - Pa e 3 

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 Run Ib/ton Ib/ton 

# 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 
Air-Tech Environmental, LLC 

Hanson Brick/PG Test Report (AT06-0396-HSC) 

June 5,2006 -Pae4 

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 IIlI 

I i~l I i~ ' I I I ~ :I Vacuum 

Line 

0.1 N H2SO4 Em t p y 

Silica Gel 

(300 grams) 

Vacuum 

Gauge 

By-pass 

Valve rValve 

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 - Page 8 

Temperature Sensor 

Heated Probe 

Air Flow r Oven 

~ 

~ 

S 

~ 

Figure 2. Method 26A Sampling Train 
Air-Tech Environmental, LLC 

Hanson Brick/PG Test Report (nr06-039'6-HBC) 

June 5, 2006 - Pa e 9 

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) yd± 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 RZ= 0.9997 

Not s ecified HCI R2= 0.9998 
Appendix A 

Field Data Sheets and Run 

Summaries 
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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 

Wet Molecular 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 0.00 
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Date VS -/D —d i Information:! 

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(Inside Far Wall to Outside of Nipple/Port) 

Ni le/Port Len h Distance B) 

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Preliminary Velocity Traverse Form and Cyclonic Flow Check 

0 4- IFC, 

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A % C) R- 2-Yb Z t 

a. -2,1 

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Average of Absolute Values of All Angles >200 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: Velocity 

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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Date j ~ I p,p ; Information: 

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(Inside Far Wall to Outside of Nipple/Port) (D 

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Nearest Upstream Disturbance ,, d 

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Traverse Point Location Form 
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 

~ ~ c~.a~ 

PL+,,), ► 2.2-s 0,35 

I in (0.z9 

IZ ~3 p. z$ 

,3 ZT n. 2-8 

~ f ~ o '2'~ 

V_ 29 

~ 
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~. 

QA Review Performed b y: Michle H. Bo yer N~~ 
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 
Results 

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Narrative Summary 

~ : .~ 
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 (H2 SO4ma.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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POST Calibratlon For. 4M6 grl C. ~ FULL Calibratlon 

BOX # : 47-13 DATE : e s ' la2 - 

Or(nce # • '51 2 YD : E 19(7~0 

Barometric : AH : 

K-Factor : 

20 176 

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