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,

comEntec 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 1237111213141720232527323334384958Executive 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

ResultsSOURCE

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 12345ENTEC 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

05/08/07Test

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 0.303 inches

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 110.05.8 g•ms 104.0 17.1 Avg. Orifice Delta H Impingers Weight Gain (Moisture) Silica Gel Impinger Weight Gain (Moisture) 108.05.4 Wimp 107.39.4 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 0.590 358.114.5 28.4 0.588 355.627.0 mg 0.590 357.023.3ENTEC 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

0.9994SamplingProcedures 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

andimpinger. 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 laboratorywhere 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.

11Method 5 Sampling

Train

Filter Exit Temperature (-248° F)

[Heated Filter, Filte7 \1 .o•dor and.robo Impinger Exit Temperature (<68 F)

Ice Bath