,. 

TOTAL FLUORIDE EMISSIONS TESTING 

ON THE KILN EXHAUST (S-1) 

AT ROCKY RIDGE, MARYLAND 

BORAL BRICKS 

P. 0. Box 1178 

COLUMBUS, GEORGIA 31902-1178 

(334) 480-2487 

August 18, 1998 

REPORT# 6015 

/ 

ANALYTICAL TESTING CONSULTANTS, INC. 

30 I Brookdale Street 

Kannapolis, N. C. 28083 

(704) 932-3193 

Distribution: 

Mr. David Johnson 

(Five copies) 

Issue Date: 

August 21, 1998 
INTRODUCTION 

This report presents the results of total fluoride emissions testing on the kiln exhaust at the Boral 

Brick facility in Rocky Ridge, Maryland. Testing was conducted on Wednesday and Thursday, 

August 5 and 6, 1998. 

Testing was conducted by ANALYTICAL TESTING CONSULT ANTS, INC. of Kannapolis, 

NC. Members of the test team were Stewart Meadows, project leader and Michael Hazeltine. 

CERTIFICATION OF RESULTS 

"By our signature we certify that the testing and the reponing of the test results contained herein are 

prepared to the best of our abilities and that, to our knowledge. the data have been calculated and reported 

correctly. No data or information has knowingly been omitted." 

Dan McCombs 

Test Report Preparation 

I 

S ~ ~.JGv.=(wr_..,) 

Stewart Meadows 

Test Team Leader 
ltg'ouolprpdr 

(19l00din) 

Bl·I'IO,Ibonllll.odd 50001·2 (17lD clin) 

83 ·Miltopyl Madtl SIOI'R Silo 81 clln) 

114 ·Miltopyl Model 510I'RSI.Io221 (144!0 din) 

Bl ·MD<r.,ul Madill SIO'IllSIJo 144 (fnliilooxlwlll ml)') B! •Aaoyul .. Modtl (rqis!rlli0<1 160135) 

Baghousc Exhaust• 

.,. 

.uorat .Br1c.K.s. .<.ocKy R10ge c 1an .. 

Process Flow Diagram and Air Emissions Diagram 

Primary Crusher l 

J 

Clay Storage Shed I Baghousc Exhaust 

Legend: 

Bagbouse 

=-.. Clay/Brick 

......... !> Outside A

Waste H

. 

. . 1-

. ·---------···+ Air Ex

*-t 

Screen Danks 

lncla 

Grinder 

Shale« 

\ 

I 

,.... 

AAAAAA 

. . . . . . 

I I I I . . 

. 

.. 

. 

. 

. 

. . 

. • • 

. . .. . 

.. . . . 

. . . . 

I 'f I I 

. . . . 

Pre--Dryer Vents 

. . . . 

Soft Mud 

Prc-Dzyer 

. • . • 

S3 

i 

!+---: 

1 Storage ' n .\ Tank 'tn Mansao= Feeders : Hand·JlTC6S I 

Pug/Sand : Shapes Mold Brick h ! I :'1 Machine ...................... •

\ 

Pug 

MUI 

(used for handpressed sbopes) 

S2 : 

• 

• 

J /'/ ,.. .. 

1 Pug Mill/Extruded / L .. 

__ Brick Machine , ...... ..-···· 

......... . 

,.../I 

,/ 

..1-

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,..... 

r+-·--·-Waste Heat ·-·-.. L··-------·-.. 

DrycriKiln : Sl . 

• • • 

I 

Manufacturin

j 1 !

V D:w.t Rxhausr Kiln Exhaust 
RESULTS, CONCLUSIONS AND COMMENTS 

A summary of some pertinent results appear in the preceding RESULTS SUMMARY. For 

additional information please consult the CALCULATIONS and DATA SHEETS sections of 

this report. 

Brick Kiln Stack Exhaust 

The mean velocity was detennined to be 43.20 per second (ftfs) through the 29.5" round exhaust 

stack. This yielded a mean actual volumetric flowrate of 12,302 cubic feet per minute (ACFM). 

The standard flowrate was calculated by applying corrections for: I) barometric pressure- 30.14" 

Hg (day 1), 30.19" Hg (day 2), 2) static pressure of the stack (-0.42" Hp), 3) moisture content of 

each individual run- AVG.=5.82%, and 4) the corresponding stack temperature- AVG.=324.! 0 

Fahrenheit. The corresponding mean standard volumetric flowrate was 7,916 SCFM. 

Total Flouride emissions averaged 0.382 pounds per hour or 12,886 ug!M3

• Production data 

provided by the plant showed the kiln process rate to be 4.54 tons per hour. This yields an 

emission rate of 0.084 pounds of Flouride per ton of bricks processed. 

5