ENTEC $ ices 

Pollution Control System Evaluation and Source Emissions Testing 

Cherokee Brick and Tile 

Macon, Georgia 

Compliance Emissions Testing 

No. 1 and No. 2 Kilns Dry Lime Adsorber Stack 

May 8, 2007 

Entec Project No.- 27157 

16-D Commerce Avenue Hueytown, Alabama 35023 Phone: (205) 491-6676 Fax (205) 491-6614 

www. entecservices, com 
Entec Services, Inc. 

16-D Commerce Avenue 

Hueytown, Alabama 35023 

Telephone: (205) 491-6676 

Fax: (205) 491-6614 

Results of the May 8, 2007 

Emissions Testing for Particulate Matter on 

No. 1 and No. 2 Kilns Dry Lime Adsorber Stack at the 

Cherokee Brick Facility located in 

Macon, Georgia 

Submitted to: 

Cherokee Brick and Tile Co. 

3250 Waterville Road 

Macon, Georgia 31206 

Attention: Mr. Jim Owens 

Entec Project No. 27157 Report Submitted: May 18, 2007 

Completed By: Reviewed By: 

for this r• 

• Lynn Beane 

f 

'•. iroO:•Ct. Manager. Technical Services Manager 

erda. e best of my knowledge all field sampling and laboratory analysis performed 

•'ls authentic and accurate. It has been checked for completeness and accuracy. 
Cherokee Brick and Tile Co. 

Table of Contents 

Section Pa_qe No. 

Executive Summary 

Emissions Summary 

Detailed Test Results 

Sampling Procedures 

Location of Test Ports 

Method 5 Sampling Train 

No.1 No. 2 Kilns Dry Lime Adsorber Field Data Sheets 

-Test Run 1 

Test Run 2 

-Test Run 3 

Control Room Data 

Test Protocol 

Quality Control I Quality Assurance Procedures 

QA/QC Checklist 

Orifice Check and Temperature Check 

Fyrite I Orsat Standardization 

Laboratory Analysis 

Equipment Calibrations 

Nomenclature and Test Calculations 

1 

2 

3 

7 

11 

12 

13 

14 

17 

20 

23 

25 

27 

32 

33 

34 

38 

49 

58 
Executive Summary 

Cherokee Brick located in Macon, Georgia, retained Entec Services, Inc. to perform a 

particulate matter emissions testing on the No. 1 and No. 2 Kilns Dry Lime Adsorber 

Stack. Mr. Lynn Beane and Mr. Ryan Harris, of Entec Services, Inc. conducted the 

testing on May 8, 2007. Representing Cherokee Brick was Mr. Jim Owens who 

coordinated testing with the control room production activity. Representing the state 

from the Georgia Department of Natural Resources was Mr. Daniel McCain. 

Entec Services, Inc. encountered no difficulties in the field collection of the samples or 

in the !aborato.n,I analysis of the samples 

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

test run compared to the maximum emission limits set forth by the Georgia Department 

of Natural Resources. Test results indicate the emissions results were below the 

emissions standards set forth by Permit No. 3251-021-0167-V-02-0, and the Brick 

MACT. 

Detailed Test Results 
SOURCE OWNER: 

PLANT LOCATION: 

SOURCE(S) NAME(S): 

SOURCE(S) CONDITION: 

SOURCE OVERVIEW 

Cherokee Brick and Tile 

Macon, Georgia 

Dry Lime Adsorber Stack 

Compliance Testing 

SOURCE(S) SHAPE: 

PROBE WASH CHEMICAL: 

SOURCE PERMIT NUMBER: 

TEST PERFORMED: 

ADDITIONAL TEST REQUIREMENTS: 

REFERENCE METHOD TESTS: 

PROJECT MANAGER 

ENVIRONMENTAL ANALYST PROJECT LEADER 

ENVIRONMENTAL ANALYST ASSISTANT 

OWNER'S REPRESENTATIVE: 

RULING AGENCY 

RULING AGENCY REPRESENTATIVE: 

•ATES TESTS CONDUCTED: 

ENTEC PROJECT NUMBER: 

Circular 

Acetone 

3251-021-0167-V-02-0 ID No. PCD01 

Particulate Testing 

Lime MACT Subpart JJJJJ 

Sample Location 

Volumetric Flow 

Molecular Weight 

Moisture Content 

Particulate 

EPA Method 

EPA Method 

EPA Method 

EPA Method 

EPA Method 

Mr. Lynn Beane 

Mr. Lynn Beane 

Mr. Ryan Harris 

Mr. Jim Owens 

Georgia Department of Natural Resources 

Mr. Daniel McCain 

05/08/07 

27157 

1 

2 

3 

4 

5 
ENTEC Sewices, Inc. 

16-D Commerce Ave. Hueytown, Alabama 35023 

INPUT TEST DATA 

Client: Cherokee Brick and Tile Job No.: 27157 

Source: Dry Lime Adsorber Stack Data Input By: Mr. Lynn Beane 

Field Data 

!Run Number 

Test Date 

Time Test Run Began Ended 

Samplin 9 Time 

Stack Area 

Barometric Pressure 

Stack Static Pressure 

Pitot Tube Correction factor 

Meter Correction Factor 

Meter Delta H @ 

Nozzle Diameter 

Symbol 

As 

Units 

Military Time 

minutes 

05/08/07 

0800-0905 

6O 

22.166 

05/08/07 

Test 

0930-1035 

6O 

22.166 

P•, in. Hg 30.09 30.09 

in. Hz0 -0.27 -0.27 

0.84 

P• 

C• 

Y 0.995 

•H(• in. H20 1.864 

On inches 0.303 

0.84 

Data 

05/08/07 

1t00-1205 

6O 

AVERAGE 

6O 

22.166 

30.09 30.09 

-0.20 -0.25 

0.84 0.84 

0.995 0.995 0.995 

1.864 1.864 1.864 

0.303 0.303 0.303 

Meter Volume vm dcf 43.615 44.268 44.693 44.192 

Meter Temperature t•, °F 66.0 76.3 83.0 75.1 

AH in. H20 1.80 1.80 1.82 1.81 

grams 110.0 

5.8 g•ms 

104.0 

17.1 

Avg. Orifice Delta H 

Impingers Weight Gain (Moisture) 

Silica Gel Impinger Weight Gain (Moisture) 

108.0 

5.4 

Wimp 107.3 

9.4 

Oxygen Concentration, dry basis 

Carbon Dioxide Concentration, dry basis 

Avg. Sq. Rt. of Delta P 

Stack Temperature 

Total particulate collected 

% 18.0 17.0 17.0 17.3 

CO2 % 3.0 4.0 4.0 3.7 

(in. H20) 

F 

(sqrt z•P)avg 0.592 

357.3 

0.590 

358.1 

28.4 14.5 

0.588 

355.6 

mg 27.0 

0.590 

357.0 

23.3 
ENTEC Services, inc. 

16-D Commerce Ave. Hueytown, Alabama 35023 

CALCULATED TEST DATA 

Client: 

Source: 

Run Number 

Test Date 

Cherokee Brick and Tile Job No.: 27157 

Dry Lime Adsorber Stack Data Input By: Mr. Lynn Beane 

Description Formulas Symbol Units Calculated Data 

Time Began-Ended 

1. Stack Pressure P•.v P,•/13.• 

2. Meter Pressure Pb• •H 113.6 

1 2 3 AVERAGE 

05/08/07 05/08/07 05/08/07 

0800-0905 0930-1035 1100-1205 

30.07 30.07 30.08 30.07 

30.22 30.22 30.22 30.22 

3. Standard Meter Volume 17.64" Y* (V•/T,•)* (Pb• ,•H t3.6 

4a. Standard Volume of Water Vapor Condensed =0.04706*w• 

4b. Standard Volume of Water Collected in Silica Gel =0.04715"w• 

5. Moisture Fraction =(v,¢{,• 

9. Molecular Weight Of Stack Gas, dry basis 0.32'(O=}+ 0.44-(co=)+0.28-(100-(O=)-(C0=)) 

10. Molecular Weight Of Stack Gas, wet basis Ma*(l -B•)+18.0*(B•) 

I. Average Stack Gas Velocity 86.49*Cp'(sqrt/•P)avg*SQRT((Ts) (Ps*Mw)) 

12. Stack Gas Flow @ Stack Conditions 60*vs*A= 

13. Stack Gas Flow @ Standard Conditions Qa*(T=t•/l's)*(ps/p=d 

Q=*(1-B,,)*(T•c•I'=)*(PJP=t,•) 

Military Time 

P= in. Hg 

Pm in. Hg 

E• fraction 

Md g/g-mole 

MI g/g-mole 

v,, R/s 

14. Stack Gas Flow @ Dry Standard Conditions Q,,• dscfm 

15. Particulate concentration @ Standard Conditions =o.01543*mtJV•=•] c,, grldscf 

21. Particulate Emissions (6O/7OOO)'c=*Q=< PMR light 

24. Isokinetic Sampling Rate, Pement 100*Vn (60*vs*A,*01 

Post Meter Orifice Cal. (EMC ALT-009 Yqa) 

% Difference, (Calibration must be within 5% of original Y-factor) 

43.984 43.790 43.662 43.812 

5.177 5.082 4.894 5.051 

0.273 0.255 0.806 0.445 

0.1102 0.1086 0.1155 0.1115 

29.200 29.320 29.320 29.280 

27.965 28.090 28.013 28.023 

41.88 41.49 41.76 41.710 

55,704 55,177 55,538 55,473 

36,155 35,886 36,016 36,019 

32,169 31,987 31,857 32,004 

0.0100 0.0095 0.0051 0.0082 

2.75 2.61 1.40 2.25 

100.88 101.00 101.12 101.00 

1.0032 0.9973 0.9976 0.9994 
Sampling 
Procedures 

The particulate and gas emission rates were determined using EPA Methods 1-5, CFR 

Title 40, Part 60, Appendix A. The calibration and quality assurance procedures of EPA 

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

Air Pollution Measurement System" Volume III Stationary Source-Specific Methods 

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

The most current version for each method (as described in the Federal Register) was 

used. 

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. 

Stack Gas Molecular Weight 

The carbon dioxide and oxygen concentrations were determined using EPA Reference 

Method 3 (Fyrite Method). A sample of the flue gas was extracted from the gas stream 

during each test. These samples were analyzed with a Fyrite gas analyzer. The 

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

dioxide content and the measured stack gas temperature. 

Moisture Content 

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

measuring the amount of condensed moisture in the glass impinger and silica gel 

impinger in the sampling train as described in EPA Reference Method 4 at the 

completion of each test. 

The moisture collection system consists of a stainless steel condenser connected to 

silica gel impinger attached to the outlet. Ice is placed around the condenser and 
impinger. The outlet temperature of the impinger is monitored and recorded throughout 

the duration of the testing to verify the temperature is below <680 F. 

Particulate Determination 

The paniculate sample train consists of a heated stainless steel sample probe and 

glass equipped with a S-type Pitot tube and thermocouple. The probe is attached to a 

sample module consisting of a heated filter compartment which houses the in-line filter 

holder equipped with a pre-weighed glass fiber filter for the collection of the particulate. 

The sample module is connected to an unheated saturated umbilical cord, which is 

connected to the stainless steel condenser for the collection of the condensed 

moisture. The sample module is connected to a control module by means of an 

umbilical cord. The control module consist of a dry gas meter, calibrated orifice, leak 

free pump, two inclined manometers, temperature controllers for the heated filter 

compartment and probe and a thermocouple indicator to monitor the required 

temperatures during the testing. 

Particulate samples are collected as follows: The sample gas is drawn through the 

sampling probe isokinetically and passed through a 3-inch Whatman glass fiber filter 

where particulates are removed. The sample gas is then passed through the umbilical 

cord to an ice-cooled condenser and desiccant-packed column, which absorbs any 

remaining moisture. The sample gas then passes through a vacuum pump followed by 

a dry gas meter. The dry gas meter integrates the sample gas flow throughout the 

duration of the test. A calibrated orifice attached to the outlet of the dry gas meter 

provides real time flow rate data. 

A representative paniculate sample is acquired by sampling for equal periods of time at 

the centroid of a number of equal area regions in the exhaust stack. The sampling rate 

is adjusted at each test point maintaining an isokinetic sampling condition. 

After the sampling is complete, the filter is removed and placed in a storage container 

for shipment back to the laboratory for analysis. The nozzle, probe liner and inlet side of 

the filter holder are quantively washed with a reagent grade acetone and stored in a 

marked and sealed container. The samples are transferred back to the laboratory 
where they are logged in and analyzed. The volume of acetone rinse is noted and 

transferred to a tarred fleaker and evaporated. The acetone-free sample is placed in an 

oven and dried at 105 °C for thirty minutes and then placed in a desiccator. After the 

sample has desiccated for twenty-four hours the sample is weighed to the nearest 0.1 

mg. The filter sample is transferred to the original petri dish in which the original weight 

was obtained and placed in a drying oven for 2 hours at 105 °C. The filter and petri dish 

are then placed in a desiccator. After the filter and petri dish have desiccated for 

twenty-four hours the sample is weighed to the nearest 0.1 mg. Visual examination of 

the samples are made to determine if any unusual characteristics of the samples are 

observed. The weight of the acetone rinse is corrected for the weight of the acetone 

blank. 
Entec Services, Inc 

16 D Commerce Ave. Hue•town AL 35023 

STACK DRAWING & TRAVERSE POINT LOCATION 

Client: Cherokee Brick and Tile Job No. 27157 

Source: Dq/Lime Adsorber Stack Input By: Lynn Beane 

Type of Traverse: Velocity (V) or Particulate (P): P Port Type Nipple Port Diameter 6.0" 

Stack Diameter, inches: 63.75 Stack Area, Ft2: 22.166 

Stack Height, feet: 100 Number of Ports: 2 

31=•k Properties: inches Duct Diameters Length of Port, inches: 8.25 

U pstream Disturbance: 170,0 2.67 Total Number of Traverse Points: 12 

Downstream Disturbance: 684.0 10.73 Number of Points per diameter: 6 

63.8 INCHES 

0.0 INCHES 

INCHES 

Point N(• 

Inside Stack Outside Nipple 

Inches Inches 

1 2.8 11.1 

2 9.3 17.6 

3 18.9 27.1 

4 44.9 53.1 

5 54.4 62.7 

6 60.9 69.2 

Adjusted points diameter > 24" no point closer than 1.0 inch 

Adjusted points diameter _< 24" no point closer than 0.5 inch 

Stack Diameters between 12-24 inches minimum points are 8 

4 points per port if the 812 diameters downstream and 

upstream criteda is met. 

11 
Method 5 Sampling Train 

Filter Exit Temperature 

(-248° F) 

[Heated Filter, Filte7 \1 .o•dor and.robo 

Impinger Exit Temperature 

(<68 F) 

Ice Bath