Stationa• •urc¢ Samp!•g

Report Brick •h Exhaust Triangle Brick Company Wadesboro,-No• C•l•a Trigon Project No. 046•05-144 March 2006STATIONARY SOURCE

SAMPLING

REPORT FOR TRIANGLE BRICK

COMPANY WADESBORO• NORTH

CAROLINA Brick Kiln K-1 Exhaust

Performed by: Trigon Engineering

Consultants,

Inc. 6200 Harris Technology

Boulevard Charlotte, North Carolina

28269 704.598.1049 Trigon Project No. 046-05-144 March 2006Stationao, Source Sampling, Triangle Brick Company May 5, 2006 Brick Kiln K-1 Exhaust, Wadesboro, North Carolina Trigon Project No. 046-05-144 I REPORT

CERTIFICATION This report, the testing details, and the f'mal results have been performed

under the supervision

and reviewed by the persons named below. Results contained

in this report relate only to the items tested. This report shall not be reproduced

in full or in part without the written consent of Trigon Engineering

Consultants, InC.

Date Signature

Bryan L. Stames Project Manager Air Monitoring

Department Trigon Engineering

Consultants,

Inc.

W. Quentin Best Quality Assurance

Manager Air Monitoring

Department Trigon Engineering

Consultants,

Inc.

Date ••//•; Signature

Paul R. Jenkins, Jr. Manager Air Monitoring

Department Trigon Engineering

Consultants,

Inc.

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TABLE OF CONTENTS

1.0 INTRODUCTION

................................................................................................................................ 4 1.1 Purpose

................................................................................................................................ 4 1.2 Outline of Test Program

...................................................................................................... 4 1.3 Test Participants

.................................................................................................................. 5 2.0 PROCESS

DESCRIPTION

............................................................................................ 6 2.1 Discussion

............................................................................. 6 Figure 1 Process Air Flow Schematic

Brick Kill Exhaust 7 3.0 SAMPLING

METHODS

..................................................................................................................... 8 3.1 Sampling

Strategy 8 3.2 Sampling

and Analytical

Procedures 8 3.3 Sampling

Ports, Traverse

Points and Cyclonic

Flow Determination 8 3.4 Stack Gas Velocity

and Volumetric

Flow Rate Determination 8 3.5 Dry Molecular

Weight Determination

................................................................................ 9 3.6 Moisture

Determination

.................................................................................................... 10 3.7 Particulate

Matter, Hydrogen

Chloride,

and Hydrogen

fluoride Sampling 11 3.9 Sampling

Ports and Points

................................................................................................ 12 Figure 2 Brick Kill Exhaust

............................................................................... 13 3.10 Quality Assurance

and Quality Control

............................................................................ 14 4.0 RESULTS

............................................................................................................................................ 16 4.1 Summary

of Results

.......................................................................................................... 16 4.2 Discussion 16 5.0 APPENDICES

.................................................................................................................................... 17 Number of pages in Appendices

87 A. Summary

of Results and Example

Calculations B. Field Data Sheets C. Laboratory

Data D. Production

Data E. Calibration

Data

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NO. 04036 Page 3 of 17Stationary Source Sampling, Triangle Brick Company At•, 5. 2006 Brick Kiln K-1 Exhaust, llZadesboro. North Carolina Trigon Project No. 046-05-144 1.0 INTRODUCTION This section describes

the purpose,

a brief outline including

the sampling

and analytical

strategy, and the personnel involved in the test program. 1.1 Purpose The purpose of this sampling

project was to determine

concentrations

and emission

rates of particulate matter, hydrogen

chloride and hydrogen

fluoride from the Brick Kiln K-1 Stack located at the Triangle

•u•t• t)• u• •mnp•mg

ano the documentation provided in this report will be used for compliance

evaluation

according

to Air Permit Number 08179T05 issued by the North Carolina Department

of Environment

and Natural Resources

(NCDENR). 1.2 Outline

of Test Program Stationary source sampling

was performed

March 14, 2006 by the Air Monitoring

Department

of Trigon Engineering Consultants,

Inc. (Trigon).

Three one-hour

sampling

runs were conducted

at the referenced source. The sampling

runs were conducted

during normal production

and operating

conditions.

United States Environmental

Protection

Agency (US EPA) Methods

1 through 5 were used for the determination

of particulate matter concentrations

and emission

rates. Method 26A was used for the determination

of hydrogen chloride and hydrogen

fluoride concentrations

and emission

rates. The specific application

of these methods will be described

in Section 3.0, Sampling

Methods.

The sampling

and analytical

procedures used in this test program

were those established

by the US EPA in standard

reference

test methods

and appropriate sampling

and analytical

procedures.

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1.3 Test Participants A list of the project participants,

titles, affiliation

and telephone

numbers

can be found below. Participant Title Terry W. Blackwell

Project Manager

Joshua A. Jones
Brian K. Nottingham

William G. Colby

Tom McKinney

Senior Environmental Scientist Environmental Scientist
President

Environmental Engineer

Affiliation Tdgon Engineering Consultants, t•c. Trigon Engineering Consultants, Inc. Trigon Engineering Consultants, Inc. Colby Engineering

& Consulting NCDENRDAQ

Contact Telephone: 704.598.1049 Facsimile: 704.598.1050
• •I twblackwell@tfigoneng.com

Telephone: 860.491.9664 Facsimile: 860.491.2211 E-mail bcolby@optonline.net Telephone: 910.486.1541 Facsimile: 910.486.0707 E-mail tom.mckinney@ncmail.net

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2.0 PROCESS

DESCRIPTION This section contains a brief description

of the brick kiln, the control devices and an air flow schematic. 2.1 Discussion Triangle Brick operates one natural gas fired kiln at its facility in Wadesboro,

North Carolina.

Ah eighteen
car shuttle is conveyed

through the kiln yielding approximately

23.81 tons/hr of bricks fired. Flue gases are withdrawn from the gas-fired

tunnel throueh• a •enlhho.r__.

! r• e,,,, •qd stack *,-.v *•'--..v •ul.,.ov,,,.,•.-•-^--•-^-•

Fig-are 1 details the air flow schematic. During testing, brick production

was at 23.47 tons per hour. Production

data wasrecorded

by Triangle Brick personnel

and is presented

in Appendix

D.

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Brick Kiln K-1 Atmosphere

Stack

•--Sampling

LocationI.D. Fan

Scrubber

Figure 1 Process Air Flow Schematic

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NO. 04036 Page 7 of 17'Stationary Source Sampling, Triangle Brick Company Brick Kiln K-1 Exhaust. l•'adesboro, North Carolina May 5, 2006 Trigon Project No. 046-05-144 3.0 SAMPLING

METHODS This section describes

the sampling

strategy, sampling

and analytical

methods,

and quality assurance/quality control procedures

implemented

during this project.
3.1 Sampling

Strategy The sampling

and analytical

procedures

used during this test program

were those established

by the US EPA. The sampling

runs were conducted

in triplicate

to validate the sampling.

Tests were conducted

3.2 Sampling

and Analytical

Procedures The US EPA methods used in this sampling

program were Method 1 for the location of sampling

ports and points, and determination

of cyclonic flow, Method 2 for volumetric

flow rate determination,

Method 3 for the determination

of dry molecular

weight of the stack gas, Method 4 for the determination

of moisture

in the stack gas. Methods

5 and 26A were used for the determination

of particulate,

hydrogen

chloride and hydrogen fluoride emissions.

A sampling

and analysis synopsis for these methods is discussed

briefly in the following subsections.

These test methods

are available

in the Code of Federal Regulations

Volume 40, Part 60 or by request from Trigon.
3.3 Sampling

Ports, Traverse

Points and Cyclonic

Flow Determination The sampling

locations

were prepared

according

to the criteria in Method 1. The duct diameters

upstream and downstream

from the sampling

ports were determined

prior to sampling.

The-number

of traverse points
was chosen with respect to sampling

port location.

For particulate

traverses

Method

specifies

a minimum of 8 traverse points for sampling

ports located >8/>2 downstream/upstream stack diameters

from flow disturbances and 24 traverse points when located >2/>0.5.

The amount of cyclonic

flow was determined according to the criteria detailed in Method 1. 3.4 Stack Gas Velocity

and Volumetric

Flow Rate Determination Method 2 is used for determining

the average gas velocity in a stack from measurements

of gas density and the average velocity head with a Type S (Stausscheibe

or reverse type) pitot tube. This method is applicable for quantifying

gas flows which meet the criteria of Method 1. In principle,

measurements

of velocity head and temperature

are performed

at the traverse points specified

by Method 1. A properly

scaled differential

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pressure gauge was selected for the range of Ap values encountered

during the traverse.

A 0 10 inches of water inclined manometer

was used as the differential

pressure gauge. During this project, the sampling

locations

met the criteria detailed in Method 1. Gas stream density was determined by Method 3. Moisture

determination

was performed

by Method 4. The principal

components of the gas velocity measurement

system were sequentially:

• A calibrated

stainless steel Type S pitot tube and Type K thermocouple;

• A 0 to 10 inch inclined manometer;

and

• An N/ST traceable

pyrometer. The apparatus

was set-up according

to manufacturer

and reference

method recommendations.

Pre-test and post-test leak checks were conducted

using procedures

outlined in Method 2, Section 3.1. Velocity head and temperature measurements

were performed

at the traverse points specified

by Method 1. The atmospheric and static pressure of the stack was also determined

for the velocity head readings.

The volumetric

flow rate calculations

used were those specified

in Method 2, Section 5. A more comprehensive

explanation

of the reference

method is detailed

in the Quality Assurance

Handbook

for Air Pollution

Measurement Systems: Volume 1II, EPA/600/R-94/038c,

(QA Handbook)

FieMProcedure

2. 3.5 Dry Molecular

Weight Determination Method 3 is applicable

for determining

carbon dioxide and oxygen concentrations

and dry molecular

weight of a sample from a gas stream of a fossil-fuel

combustion

process.

This method may also be applicable

to other processes

where it has been determined

that compounds

other than carbon dioxide, oxygen, carbon monoxide, and nitrogen are not present in concentrations

sufficient

to affect the results.
In principle,

a gas sample was withdrawn

from the emission

source by multi-point,

integrated

sampling.

The collected sample was then analyzed

for percent carbon dioxide, percent oxygen, and percent carbon monoxide. The dry molecular

weight determination

was performed

by an Orsat analyzer. During this project, the gaseous components

were collected

using a Method 3 sampling

system following the analytical

procedures

outlined

in the reference

method.

The principal

components

of the sampling system were sequentially:

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• A stainless steel probe;

* A one-way squeeze bulb, to transport

the sample to the Tedlar bag;

• A saturaior tube to remove particulate

matter and excess moisture;

and

• A leak-free Tedlar bag equipped

with a double-end

shut-off quick connect. The analysis

was performed

with an Orsat type combustion

gas analyzer

within 8 hours of sample collection. The dry molecular

weight was calculated

using Equation

3-1, Section 7 of Method 3. The analyzer was maintained

and operated

according,

to the instn]atinn•

r•c•amm•nrl•,cl

by •-1-,

.e in accordance

with Method 3 criteria. The analyzer was leak-checked

according

to Section 6 of Method 3. The oxygen reagent was validated

by analyzing

a sample of ambient air which must meet the specifications of 20.9% + 0.3%.
3.6 Moisture

Determination Method 4 involves the determination

of stack gas moisture.

The moisture

content is used to correct the emission concentration

or mass emission

rate to a dry. basis. EPA Method 4 and Field Procedure

4 of the QA Handbook

was used to measure

stack gas moisture

content.

Field Procedure

4 provides

detailed information on the application

of Method 4. Preliminary flue gas moisture

content (for purposes

of setting the isokinetic

flow rate) was determined

using wet bulb/dry

bulb thermometers

and partial pressure,

vapor and saturated

vapor pressure equations.

This technique is described

in Method 4 and is summarized

below:

• Moisten the wet bulb thermometer

wick with deionized

water;

• Insert both thermometers

into the flue gas stream and monitor the wet bulb temperature;

• When the wet bulb temperature

has stabilized,

record both the wet bulb and dry bulb thermometer temperatures;

and

• Calculate

the flue gas moisture

content (PMV) using the appropriate

equations. The moisture

content for emission

rate calculations

was determined

in conjunction

with the Method 5/26A isokinetic sampling

train. The reference

method involves

the withdrawal

of gaseous and particulate pollutants from the emission

source at an isokinetic

rate using a Method 5 sampling

system. The sampling and analytical

procedure

for reference

Method 4 will be discussed

in detail in the following

section with the isokinetic sampling

procedure.

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North Carolina May 5, 2006 Trigon Project No. 046-05-144 3.7 Particulate

Matter,

Hydrogen

Chloride,

and Hydrogen

fluoride

Sampling Testing for particulate

matter, hydrogen

chloride,

and hydrogen

fluoride was performed

according

to Method 26A procedures.

Gaseous

and particulate

pollutants

were withdrawn

isokinetically

from the emission source and collected

in a multi-component

sampling

train. In principle,

particulate

matter that was condensed at or above the filtration

temperature

of approximately

248 degrees Fahrenheit

was collected

on a tared quartz fiber filter. The gaseous components

were then bubbled through a measured

volume of 0.1N sulfuric acid and O.1N sodium hydroxide

to determine

the moisture,

hydrogen

chloride,

and hydrogen

•,,•u• •uul•:•.

xne principai

components

of the sampling

system were sequentially:

• A borosilicate

glass sample nozzle and probe liner;

• A heated (248°F ±25°F) probe and filter assembly

with tared quartz fiber filter;

• An impinger

train consisting

of five sequential

impingers.

/mpingers

one and two containing 100 ml each of an absorbing

solution

consisting

of dilute sulfuric acid (0.1N H2SO4). Irnpingers three and four contained

100 ml of dilute sodium hydroxide

(0.1N NaOH) followed by a fmal impinger

containing

200 grams of silica gel; and

• A metering

system capable

of maintaining

an isokinetic

sampling

rate and accurately determining the sample volume according

to specifications

in APTD-0581. Sample clean up began immediately

after each test run. The filter, which collected

the sample, was carefully removed

from the Teflon filter support and sealed in a Petri dish. The nozzle, probe liner, and front filter-half

of the filter assembly

were rinsed with acetone into a glass storage container,

which was sealed, and the liquid level marked.

The sample containers

were transported

to Trigon's Air Quality Laboratory in Charlotte,

North Carolina

for particulate

matter analysis. Hydrogen chloride and hydrogen

fluoride were collected

in the 0.1N sulfuric acid solution in impingers

one and two. The liquid in the fn-st two impingers

was measured

to the nearest milliliter

and recorded

in order to determine

the moisture

content. The collected

sample was placed in a high-density

polyethylene

(HDPE) storage container

along with the deionized

water rinse of impingers

one, two and connecting

glassware.

The container was sealed and the liquid level was marked.
The 0.1N sodium hydroxide

solution in impingers

three and four were used as a scrubber

to protect the sampling console.

The liquid in these impingers

as well as fifth impinger

was •neasured

to further
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content and later discarded.

The moisture

collected

by the silica gel in the fifth impinger was determined

to the nearest 0.1 gram. Collected

condensate

measurements

were recorded

on the "moisture determination

and sample recovery

data analysis"

form. The samples were then shipped to Element One Laboratories

of Wilmington,

North Carolina

with chain of custody documentation

where they were analyzed

by ion chromatography.

Results of the hydrogen

chloride and hydrogen

fluoride analysis along with Element One's quality assurance

data package can be found in Appendix C.
The particulate

matter analyses began by transferring

the acetone samples to tared beakers.

These samples
were taken to dryness, and then placed in a desiccator

along with the filters for an initial drying period of 24 hours. The particulate

mass was determined

gravimetrically.

The tare weights of the filters and beakers were subtracted

from the fmal weights to determine

the gross particulate

weight.
An aliquot of the reagent grade acetone was analyzed

to determine

the blank correction

factor. The acetone rinse (corrected

for the blank) was added to the filter catch to obtain the total particulate

weight.

The particulate samples and method blanks were analyzed

by Trigon Engineering

Consultants,

Inc. personnel. The laboratory

analyses and chain of custody documentation

can be found in Appendix

C. 3.9 Sampling

Ports and Points The dimensions

of the stack and the location of the sampling

ports and points are detailed in Figure 2. Method 1 sampling

criteria was maintained.

The stack cross section was divided into 24 equal areas. The ports were labeled A and B. During the test runs each point was sampled for 2.5 minutes, which yielded a total test time of 60 minutes.

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272" Brick Kiln Exhaust

A B

SECTION

K-K

62.75"

Not to Scale Figure

2 Location of Sampling

Ports and Points

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NO. 04036 Page 13 of 17Stationary Source Sampling, Triangle Brick Company May 5, 2006 Brick Kiln K-1 Exhaust, lYadesboro,

North Carolina Trigon Project No. 046-05-144 3.10 Quality

Assurance

and Quality

Control Trigon has established

quality assurance

and quality control (QA/QC)

guidelines

for providing

quality sampling and analytical

data from source tests. These QA/QC procedures

were implemented

to ensure the acceptability and reliability

of the data generated.

In summary,

an appropriate

degree of data quality was maintained

throughout

this project. Leak checks and isokinetic QA criteria were met. The sampling

trains were leak checked prior to and immediately

after
•,,,,,• ,•m•u•

•na•p•Ja•g

trams were less than the maxtmum

criterion of 0.02 cubic feet per minute. The sampling

rates were also within the 100% +10% criterion.

Quality control procedures for the particulate

matter determinations

have included the analysis of an acetone rinse blank, which must be less than 0.001% for the acetone residue.

Spike and recoveries

were performed

for the sampling methodologies used. An analyte spike was added to a portion of a prepared

sample and recovered

to within 70 and 130 percent of the known concentration.

The results of the QA criteria for this project are summarized in the following

tables and can be. Detailed

results of the method blanks are reported

in Appendix C withthe laboratory

data.
Isokinetic Quality Control Actual Criteria Brick Kiln 5/26A Train Post-Leak

Check 5/26A Train Isokinetics

Run 1 Run 2 Run 3 0.003 0.002

0.004 96.7 100.0

101.4 Post-Test Meter Calibrations < 0.020 cu. Ft. 100+ 10%
Post Meter Calibration

(1 + 0.05) Meter Box 300.045

Y 1.02

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•Vorth Carolina May 5, 2006 Trigon Project No. 046-05-1,t4 Laboratory Quality Controls Acetone Rinse Blank

Actual

Criteria 0.00034 %

< 0.001% HC! Duplicate

Analysis RPD/RSD% 26A Boiler Run 1 Run 2 Run 3 7.0% 2.0%

0.9%

Criteria<10% HCi Spike Recovery Percent Recovery Boiler Criteria 26A 106% + 10% HF Duplicate

Analysis RPD/RSD% 26A Run 12.5% Boiler Criteria Run 2 Run 3 0.2% 2.6%

<10% HF Spike Recovery Percent Recovery Boiler 26A 87% Criteria
+ 10%

Field data and f'mal laboratory

results were entered into Trigon's

Air Quality Data System by an environmental scientist,

independently

audited by the Project Manager,

and reviewed

by the Quality Assurance Manager

for verification

of data. After QC review by the QA Manager,

the Technical

Services Manager verified the f'mal report for completeness

and reasonableness

of data. The report was returned to the Project Manager

for review and preparation

of the final draft. The report requires the signature

of the Project Manager, Operations

Manager,

and the Department

Manager

before release to the client. Data and final reports are archived in a secured area for a minimum

period often years. Trigon's field and laboratory

test equipment

has been maintained

and calibrated

in accordance

with quality assurance procedures

established

by the US EPA in the QA Handbook.

Equipment

calibrations

including pre-test and post-test calibration

data are presented

in Appendix

E.

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NO. 04036 Page 15 of 17Stationary Source Sampling, Triangle Brick Company Brick Kiln K-I Exhaust, Wadesboro, North Carolina May 5, 2006 Trigon Project No. 046-05-14,1 4.0 RESULTS This section presents

a summary

of the particulate

matter, hydrogen

chloride,

and hydrogen

fluoride sampling. Detailed

sampling

results and example

calculations

for the test program

can be found in Appendix A. Field data sheets and sample recovery

documentation

are presented

in Appendix

B. 4.1 Summary

of Results The table below is a synopsis of the sampling

conducted

at both locations. Summary of Results
••• Brick Kiln Emission Rate

EmissionRate Pollutants gr/dscf*

Ibs/hr Particulate Matter

0.0092

2.03 Hydrogen Chloride

0.0028

0.61 Hydrogen Fluoride

0.0006

0.12 *grains per dry standard cubic foot

4.2 Discussion This sampling

program

was performed

to demonstrate

the performance

of the Brick Kiln Exhaust with regard to Air Quality Permit No. 08179T05.

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NO. 04036 Page 16 of 17Stationary Source Sampling, Triangle Brick Company Brick Kiln K-I Exhaust, tVadesboro, North Carolina May 5, 2006 Trigon Project No. 046-05-144 5.0 APPENDICES This section contains

detailed

supportive

documentation

that encompasses

the relevant aspects of the emission test program.

Its contents

serve as the foundation

for [he test report. The emission

test report presents a summary

of the information

gathered

during the sampling

activities.

The information

contained in the appendices

is necessary

to facilitate

the review of the emission

test report and determine

whether proper procedures

were used to accomplish

the test plan objectives.
Dcfcnsible data and th• subsequent

pollutant

concentrations

and emission

rates •s one of the primary objectives of any emission

test program.

To this end, the test results, example calculations,

field data sheets, sample recovery,

laboratory

•-esults, chain of custody documentation,

and equipment

calibrations

have been provided to support these objectives.

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APPENDIX A

SUMMARY OF RESULTS

AND EXAMPLE

CALCULATIONSColby/Triangle Brick Wadesboro, North Carolina Trigon Project No. 046-05-144 Paqe 2 of 8Kiln Exhaust

Run Number SUMMARY

OF RESULTS EPA METHOD

26A Determination of Hydrogen

Halides & Halogens with Particulate

Emissions 2 3 Average Sample Identification

VwcBwsP•4vM•D%0•%co•%C0M•Ms
APST•VsAQsoQswD. Net Time of Test, minutes Sample Time, 24-hour clock
Static Pressure, in. Hg Stack Pressure, Absolute, in. Hg Actual Meter Volume Sampled, cu. ft. Avg. Delta H, in. H20 Avg.Gas Meter Temp., Deg. F Volume Sampled at Stand. Cond., cu. ft. Volume of Water Collected,

ml Volume of Water Vapor at Std. Cond.,SCF Moisture Content of Gas Stream Percent Moisture in Stack Mole Fraction of Dry Gas Percent Oxygen, Dry Percent Carbon Dioxide, Dry Percent Carbon Monoxide,

Dry Mole. Wt. Stack Gas, Dry Basis, lb/lb mole Mole. Wt. Stack Gas, Wet Basis, lb/lb mole Pitot Tube Constant Avg. Sqrt. Delta P, in. H20 Avg. Stack Temp., Deg. F Avg. Stack Velocity, fl/see Area Stack, • Gas Volume Flow, Dry Std. Cond. CFM Actual Gas Volume Flow, CFM Gas Volume Flow, Wet Std. Cond., CFM Sample Nozzle Diameter,

inches 5144-01

5144-02

5144-03 3/14/2006 3/14/2006

3/14/2006 60 60

60 0942-1125 1141-1250

1315-1430

•.o..• •.O• -0.027 -0.027

-0.027

-0.027 29.853 29.823

29.823

29.833 39.455 35.379

36.209

37.014 1.50 1.06

1.10

1.22 59.0 71.1

69.0

66.4 40.233 35.181

36.154

37.189 98.1 84.7

81.6

88.1 4.62 3.99

3.84

4.15 0.103 0.102

0.096

0.100 10.3 10.2

9.6

i0.0 0.897 0.898

0.904

0.900 10.83 10.97

11.37

11.06 5.77 5.53

5.33

5.54 0.00 0.00

0.00

0.00 29.356 29.324

29.308

29.329 28.187 28.171

28.221

28.193 0.84 0.84

0.84

0.84 0.539 0.457

0.459

0.485 359.0 361.2

359.8

360.0 38.2 32.4

32.6

34.4 21.48 21.48

21.48

21.48 28417 24049

24351

25605 49250 41779

41963

44331 31679 26775

26939

28464 0.310 0.310

0.310

0.310

Trigon Engineering

Consultants,

Inc.Colby/Triangle Brick Wadesboro, North Carolina

MwHCIm•HClm,HC1CsC,C, Trigon Project No. 046-05-144 Paqe 3 of 8Eitn Exhaust SUMMARY OF RESULTS EPA METHOD

26A Determination of Hydrogen

Halides & Halogens with Particulate

Emissions

Mwt•Run Number 1 An Area of Nozzle, f• 0.00052 I Percent Isokinetic 96.7 MB No. Meter Box Nmber 300.045 AH@ AH@ of Meter Box 1.68 Yqa Alternative

Method 5 Posttest Calibration

(ALT-009)

1.06
•-•,•llt •.x•c• Ak 96.8 Front Half Analysis

Non-Condensible

Particulate

Matter m. Non-Condensible

Catch, mg 27.9 C, Non-Condensible

Concentration,

gr/dsef

0.0107 C,s Non-Condensible

Concentration,

gr/acf

0.0109 CAW Non-Condensible

Emission Rate, Ibshar

2.60 Hydrogen Chloride Concentration

and Emission Rate Molecular Weight of Hydrogen

Chloride, g/mole

36.46 Hydrogen Chloride Catch, ug 7,860 Hydrogen Chloride Catch, mg 7.86 Hydrogen Chloride Concentration,

ppmv

4.55 Hydrogen Chloride Concentration,

mg/dsem

6.90 Hydrogen Chloride Concentration,

gr/dscf

0.0030 Hydrogen Chloride Concentration,

gr/aef

0.0031 Hydrogen Chloride Emission Rate, lbs/hr

0.73 Hydrogen Fluoride Concentration

and Emission Rate Molecular Weight of Hydrogen

Flouride, g/mole

20.01 Hydrogen Flouride Catch, ug 1510 Hydrogen Fluoride Catch, mg 1.51 Hydrogen Fluoride Concentration,

ppmv

1.59 Hydrogen Fluoride Concentration,

mg/dscm

1.33 Hydrogen Fluoride Concentration,

gr/dscf

0.0006 Hydrogen Fluoride Concentration,

gr/acf

0.0006 Hydrogen Fluoride Emission Rate, lbs/hr

0.14

2

3 Average 0.00052 0.00052

0.00052 100.0 101.4

99.4 300.045 300.045

300.045 1.68 1.68

1.68 1.01 1.00

1.02 •9.i 107.1

101.0
20.4 18.5

22.3 0.0089 0.0079

0.0092 0.0089 0.0079

0.0092 1.84 1.64

2.03
36.46 36.46

36.46 6,360 5,820

6,680 6.36 5.82

6.68 4.21 3.75

4.17 6.38 5.69

6.32 0.0028 0.0025

0.0028 0.0028 0.0025

0.0028 0.57 0.52

0.61
20.01 20.01

20.01 1360 1230

1367 1.36 1.23

1.37 1.64 1.44

1.56 1.37 1.20

1.30 0.0006 0.0005

0.0006 0.0006 0.0005

0.0006 0.12 0.11

0.12

Trigon Engineering

Consultants,

Inc.Colby/Triangle Brick Wadesboro, North Carolina Trigon ProjeetNo.

046-05-144 Paqe 4 of 8gl],, Exhaust SUMMARY OF RESULTS EPA METHOD

26A Determination of Hydrogen

Halides & Halogens with Particulate

Emissions Example Calculations

Run 1 Stack Pressure, Absolute,

in. Hg Ps Pb• + Pg Volume Sampled at Stand. Cond., eu. ft. 17.647 * VM * (P•, + AH / 13.6) Vs-•- TM + 460 29.853

40.233 Volume of Water Vapor at Std. Cond.,SCF Vwc 0.04709 * Vc Moisture Content of Gas Stream Vw¢ Vsro + Vwc Percent Moisture in Stack 100 * Vwc PMV Vs-m + Vwc Mole Fraction of Dry Gas 100 PMv100 Mole. Wt. Stack Gas, Dry Basis, lb/lb mole Md 0.44 * %CO• + 0.32 * %02+ 0.28 * (100 %CO• %02) Mole. Wt. Stack Gas, Wet Basis, lb/lb mole Ms=Md * (1 -BwJ+ 18.0 * Bw, Avg. Stack Velocity; ft/sce

(Ts + 460) Vs 85.49 * Cp * APS * SQRT ----.(Ps * MJ Gas Volume Flow, Dry Std. Con& CFM 1058.82 * Vs * A * Ps * (1 Ts + 460 Actual Gas Volume Flow, CFM Q•=Vs*A* 60= Gas Volume Flow, Wet Std. Con&, CFM Q• Qs•* [1/(1-B•s)] Area of Nozzle, • Ao ((Do / 2)^• * 3.14159)/144 Percent Isokinetic0.0945

* (Ts + 460) * V•o 0 *Vs * Ps * (1 B•) * 4.62

0.103

10.3

0.897

29.35628.187

38.2

28417

49250316790.00052
96.7
Trigon Engineering

Consultants,

Inc.Colby/Triangle Brick Wadesboro, North Carolina Trigon Project No. 046-05-144 Page 5 of 8T,.iln Exhaust SUMMARY OF RESULTS EPA METHOD

26A Determination of Hydrogen

Halides & Halogens with Particulate

Emissions Front Half Analysis

Non-Condensible

Particulate

Matter Non-Condensible Concentration,

gr/dscf (At Standard Conditions) Cs 0.0154 * m, / VsrD 0.0107 Non-Condensible Concentration,

gr/acf (At Standard Conditions) C,, 0.0154 * m, / VM 0.0109 Non-Condensible Emission Rate, lbs/hr (At Standard Conditions) C^w 0.00857 * Cs * QsD Hydrogen Chloride Concentration

and Emission Rate Hydrogen Chloride Concentration,

ppmv Cs Cm / MwHCI * 24.05408 Hydrogen Chloride Concentration,

mg/dsem Cm mugHCl*0.001

/ Vsr• * 0.0283160502 Hydrogen Chloride Concentration,

gr/dsef Cs 0.0154 * mu•HCt *0.001/Vsra Hydrogen Chloride Concentration,

gr/aef (At Standard Conditions) C= 0.0154 * m,HCI / VM Hydrogen Chloride Emission Rate, lbs/hr (At Standard Conditions) C^w 0.00857 * Cs * Qsl• Standard Conditions

68 Deg. F, 29.92 in. Hg 2.60

4.55
6.900.0030

0.0031

-0.73

Trigon Engineering

Consultants•

Inc.|||

APPENDIX

B

FIELD DATA SI•ETS Page 6 of 87Samphng Location. EPA Method I Page 7 of 87 Determination of Sampling

Ports and Points /'-ti'•v,•l £ •X•.•. City/State

•-•=•¢•o I•'• • • Date 31q'-//o•, Sampling Location Dimensions,

in inches: From Far Wall to Outside of Port {o•. •" Nipple Length • .7 S' Depth of Duct

L ?-.'35" Width (Rectangular

Duct) Equivalent Diameter Calculation

(DE): 2 x Length x Width

2 DE Length + Width j
Distance to Ports From Nearest Flow Disturbance: Upstream A Downstream

B Dimensions in Inches

•."! 7_

?..7 "2. Duct Diameters

•H. 33 •"

•. "5_%,.• Stack Area, in Square Feet "?..t q'3 k,, Calculations By •

10 12 2.6 2.1 8.2 6.7 14.6 11.8 22.6 17.7 34.2 25 65.8 35.6 77.4 84.4 85.4 75 91.8 82.3 97.4 88.2 •:• •o•'•L• 93.3 4 6 8 6.7 4.4 3.2 25 14.6 10.5 75 29.6 19.4 93.3 70.4 32.3 B5,4 67.7 95.6 80.6 E 89.5

!i!' :. ::' Location.of.Traverse

Points in Rectangu!•,i"

Stack• •i 2 3 4 5 6 7 8 25 16.7 12.5 10 8.3 7.1 6.3 2 75 50 37.5 30 25 21.4 18.8 3 • 83.3 62.5 50 41.7 35.7 31.3

, 87.5 70 58.3 50 3.8 64.3 56.3

Audited by:"•)'•

Date: q h"z• Ib q,o

Stack Diameter 12 24 inches Relocate to 0,50 inches from stack wall Stack Diameter 24 inches Relocate to 1.00 inches from stack wallEPA Method

2 ,Pa•e•

of 87 Determination of Stack Gas Velocity,

Volumetric

Flow Rate and t.yctomc

• tow Sampling Location K•b'• o Run Date Barometric Pressure, in. Hg "•. •'. Static Pressure, im H20 Pitot Tube Coefficient City, State Operators Time i'4oo Pitot Tube I.D. No. zoo. oq Date Calibrated

• / o •, Leak Check, in. H20 <0.1 @ *,o/-q.• Field Data X•wr•Number

Averages" Ap, at 0 RefereaceCydonic

Flow DeterminationAng• Which Yields Null oo.o O,O 0,00.0 0', O 0,•O• i)0,o0,0O.C•0,o 000

o 0 o

©0 0

• o

Stack Temperature,

Dry, °F (A) Difference (A B) Stack Temperature,

Wet °F 03) Preliminary Percent Moisture Comments

Audited by:"•'•

Date: •'•EPA Method

3 Molecular

Weight

Determb•ation

Data Analysis ClientName :•.•,3•I•-.•

/ •¢'f "•:t--]g.18 't•..•¢ ?•

Proj•tNmber

(i4 • •- I•q Page 9 of 87 Ci•/S•e •c•S•ro

3 • S•ple Date S•pl•gLoc•on •: • Ope•or ,TA• S•ple •e • Tedl• B• • Mulfipo•t

• S•e Po•t Fuel •. • •ai• T•e O•

Sed• # •-.•,:•

• •gen Ca•bmfion

•eck M•t Be 20.9 • 03% •al•r Le• Chec• • Pipe•e •d Bubbler •vels LeVee?

• B•e•e • R• # •or S• de • S•p•g T•e (24 Ho• Clock) GaS ': Re•U•iel

Replete2 Actual Net Actual Net Actual

Net

•-• .q .:': •.i00;•:. •.q

•AveragePercent

Actual., Net- Actual

Net: Note: Calculate the Fo before evacuating any bag samples. Compare the Fo to the expected fuel values, ffa discrepancy exists, reanalyze the sample. The Fo example calculation

is shown below: Fo i.-I q Run # and/or Sample ID

C.

Sampling Time (24 Hour Clock)

CO

Note: Calculate the Fo before evacuating any bag samples. Compare the Fo to the expected fuel values. Ira discrepancy exists, reanalyz• the sample. The Fo example calculation

is shown below: Fo i. Run # and/or Sample ID

"..•

Sampling Time (24 Hour Clock)

O•O0
Note: Calculate the Fo before evacuating

any bag samples. Compare the Fo to the expected fuel values. Ifa discrepancy exists, reanalyze the sample. The Fo example calculation

is shown below: Fo 20.9% %O: F % CO•

Anthracite Coal and Lignite Bituminous Coal Distillate Oil Residual Oil Ranges:For:Comm6n

Fui•ls 1.016- 1.130

Wood 1.000- 1.120 1.083 1.230

Wood Ba•k

1,003 1.I30 1.260 1.413

Natural Gas

1.600 1.836 1.210 1.370

Propane 1.434- 1.586

Audited by.•

Date:EPA Method

26A Moisture

Determination

and Sample Recovery

Data PA•Ny•i•

of 87 City/State •,• ¢ •e%•x9 Sampling Location

• • ¢) Clean-Up Box Number

(£• Chain of Custody: Date Received Sample Date Recovery Date

•'•/1• Received By

Run Number Sample ID Number Sample Box Number Probe Number Equipment

Documentation (-
Analysis of Moisture

Recovery Reagent Recover•

Container

# R • /• R 3 /• Impinger Absorbing

Solution Description of Reagent Reagent Level Marked? Final Volume, ml Initial Volume, ml ...•t....c...o..•.•.•...v..,o.,!•:..• Reagent Recovery

Container

# Impinger Absorbing

Solution Description of Reagent Reagent Level Marked? ,Final Volume, ml Initial Volume, ml Net Condensed

Volume, ml Silica Gel Recovery

Container

# Percent Silica Gel Spent Final Weight, g

9..0 •', [ •(•)Q ,eft--

• • (o. 6 Initial Weight, g •...,........A...•e•.•.•...•.•.•.•.,...S. •.:....!

•.,.,.Z

....6.......,,6 Total Reagent Cone•ted,

g Recovery Container

# Rinsing Solution Sample Container

Sealed? Liquid Level Marked? Sample Recovery
(.i Reagent

Blanks

•--- Abgorbing Reagent Blank Absorbing Blank Identification

# Absorbin• R:•'agent Blank -'A-bsorb-hag--" ]•iank Identification

# Anal•t•fi•itials Reviewer Initials Rinsing Blank Identification

# Rinsing Reagent Blank Rinsing Blank Identification

# ••.Isokinetic Field Data Sheet- EPA ,•lethod

•/•(.- /t Client (.•o[•c• / Tr :e.•-.•ie •, :•k R•N•be•age

11 of 87 Ci•/State •{• •o •.. • • Date • [ •/0 • S•pl•g Loea•on •; • Ope•to• • •¢
Bar. Press., In. Hg "•" •

NOMOGRAPHSET-UP:

KFactor •" 0•" Static Press., In. H20 o- "•-'/ AH@ I, •'•- y=.[. O• Avg. A P Meter Box No. 3 ':•. Oq5

Meter Temp. Sample Box No. "/--

Stack Temp, •-•.4•"

Desired Nozzle O,'5•-40 Probe/PitotNo. °L,•o, •a•4

Pitot Coeff.

0.84

NozzleNo.

•'•e,a• Probe Temp. Setting 2.50

% Moisture S.ample ID No. "•lqq- O C Factor LEAK CHECKS Pre-Test O. OO 3 @ • In. Hg. Post-Test 0. O o • @ • In. Hg. Pre-Tcst Pitot <0.1 @ • In. H•O Post-Test Pitot <0.1 @ • •n. H20 NozzleCalibmtion 0.5•. O,•/O,•iO Nozzle Diameter O.•i•

Observer T•,•O/A•f.'•.?•,()//

q

z_ 37..5 Otifi•.

Dry Gas Pump

stad•:. P•obe Filter

Imp: Setting AH

Meter Vacuum

T•iiiii:: Temp

]3i•k: Temp. :::. Inchds/-l•.O.

::. Temp.°l?

.inches:

.°F:. i. :°F, °F :°F Ideal-:: Actual:.

<.' . Hg: :::•;:::':.

:"

:

I,o tI,o6

Continents: Isokinetic Check: •OO Audited by:/"-P•-•

Date:City/StateSampling Location lsokinetic

Field Data Sheet- EPA 5lethod

Pago_ 12 of 87 Run Numeer Date 3•1• Operators
Bar. Press., In. Hg ,•'. I• 0_•

NOMOGRAPH

SET-UP: K Factor LEAK CHECKS Static Press., In. HE0 0. :•'• AH @ •.•_• Y .•"•L) Avg. A P •-), •

Pre-Test 0..•", & @ • Met•rBoxNo. "•3. •'.-• •-- MeterTonp. Sample Box No. "?

Stack Temp. Pro•itot No. Z •, ty-•

Pitot C•ff.

0.84 Probe Temp. Se•g •o

% Mois•e

•" •' S•ple • No. •tqq- •'• C Factor F••qO• St• T;• • In. Hg. Ref. A P t'•,•',D,

qO Post-Test O- O0"& @ •_ In. Hg. Desired Noz•e

'•O •3_g /----'l Pre-IestPitot

<0.1 @t'5-3/-h'4

In.H•O Nozzle No. •| ¢, :•

Post-Test Pitot <0.1 @ • In. H20 NozzleCalibratiun ,D.%io., O,51a Nozzle Diameter ,,.9, .• c) Observer EndTLmc 2.•,>

Agency
Point:, [::Time

DryGas:il

:! Pitot I:i': :oHae• .:.. D•Gas:

Pump.

S•dk Probe Me•er Reading

Settin•AH

Meter Vach•

Tcinp: Temp Cubic Feet ::A P I Inches:H20..

Temp. OF Inches-

°F. °F ":m'.H•O/l Ide• i: Actual..

H" g:'..,
.

i'

3 5, • r).-)

o, Z. S" 'q ")-5 •i Ifl. "5 z o.

•, )z.,s q-z.-z_.'S(/

o.

qq•,.qq o. Zo q-q$. q 5" ,3- zo (-o "-iqq .q"•q Filter

Imp..Temp Bo•x. !i. t• i.'co

t.%• I.Z• qo

•. o 3 •3 zq• ZS• qo o.• o,'•

•0

I.OL I.OO

(.O• I. oo
I.o• I. oo •3

Z.• •.o• boo

I.o• •.o0 {. o• I, •0

Comments: Isokinetic Check: •'• q. "5
Audiled by .-•x'e•-• Dale:Isokinetic Field Data Sheet EPA Method

P•g• 13 of 87 Run Number DateOperators ;• • ||| Bar. Press., In. Hg "•_ci Static Press., In. H20 Meter Box No. Sample Box No. Probe/Pitot No. Probe Temp. Setting Sample ID No.

AH@ i.•g Y= Meter Temp. •0 Stuck Temp. Pitot Coe•

0.84 % Mois•e

0 C Factor • LEAK CHECKS
Ref. A P -.'y:-L-'•

• •-• Post-TestO.(•

0 t] @ • •. Hg. Des•ed Nomle •d

P•-T•t Plot <0.1 @ •[O/- e• H20 No=le No. • •

Post-Test Pitot <0.1 @ • •. H2u No•le C•mtion

O. • •0 O, •[0, O, • iO No•e D•eterO,

ol b Obeyer • g•C•;•I •dw• /q'3•

Agenoy ••

• Sample

Clo•k

Meter

Reading Point :• Tim•

Cubld-FeetL-

APIn. H20,, o

•. •' •" •.• i. 71

,, 3 ,qo

•z z•.•

1•00

,• /
8 co.s

•i,fi 5

. •o I'Z r,do

,, ss Ori•::i

DaOas

Pu•p Setting .•

Meter vae•um Inches I-l•O :- Temp. °F Inchd§;:i

• Ro o5 I,o•

70 Filter Stack Probe

Imp• T• Td•b

Bo• Temp

3(0 •q zqo

5q

•6o 23•

•3 ul St/.

Comments: Isokinetic Check: Audited by: •'•t'• Date:APPENDIX C

LABORATORY DATA Page 14 of 87Page 15 of 87Colby Brick, Wadesboro,

North Carolina Kiln Page 16 of 87 April 10, 2006 Trigon Project No. 046-05-144 | EPA Method

5 Particulate

Determination

Data Analysis Client: Colby/Triangle

Brick City/State: Wadesboro,

North Carolina Sampling Location:

Kiln Clean-Up Box Number: M5 Chain of Custody: Date Received:

03/20/06 Analytical Balance ID: Sartorius Serial No. 39120051

Project No.: 046-05-144 Samples Collected On: Samples Recovered

By: Sample Recovery Date: Received By: ADM Class S Weight Set ID: 03/15/06 TB03/15/06 Locked?:

Yes Troemner4563 Analysis of Particulate

Recovery Sample ID Number

5144-01

5144-02

5144-03 Filter Number

Q908

Q907

Q909 480.7 478.8

494.1 480.3 478.8

494.0 467.4 468.9

482.7 Final Weight, mg Reweigh, Final, mg Initial Weight, mg Reweigh, Initial, mg Average Final, mg Average Initial, mg Net Filter Catch, mg

467.1

469.2

483.1 480.5 478.8

494.1 467.313.2 469.19.7

482.911.2 Beaker Number

213

217

219 Acetone Level Marked

Yes

Yes

Yes 115,255.8 102,685.3

114,621.5 115,256.3 102,685.0

114;621.2 Final Weight, mg Reweigh, Final, mg Im.'fial Weight, mg Reweigh, Initial, mg Average Final, mg Average Initial, mg Acetone Blank, mg

115,241.8115,241.7 115,256.1115,241.80.4

102,674.7 102,675.0 102,685.2102,674.910.4

114,614.7 114,614.2 114,621.4114,614.50.4 Net Front Rinse, mg

14.7

10•7

7.3 ITotal Particulate,

mg

27.91

20.41

18.51 Gravimetric Documentation Date of Analysis Time of Analysis Analyst iDesie. Rel. Humidity,

% Lab. Temperature,

°F Bar. Press., In. Hg Lab. Rel. Humidity,

% InitialO3/09/O60932ADM

Reweigh 03/10/061357ADM

Final03/23/060912ADM

Reweigh 03/24/060819ADM I0 10

24

25 71 71

73

74 29.00 28.94

29.26

29.03 30 37

26

27 Blank Acetone

A nalysis Blank Beaker Number

239 Beaker Volume, ml

150 Acetone Cone., %

-0.00034 Analyst Initials

ADM Auditor Initials

WQB

Final Weight, mg Reweigh, Final, mg Initial Weight, mg Reweigh, Initial, mg Acetone Residue, mg

99,051.899,051.6i99,052.099,052.2-0.4 TRIGON ENGINEERING

CONSUL TANTS, INC.| Page 17 of 87 Trigon Engineering Consultants, Inc. 6200 Harris

Technology

Boulevard Charlotte, NC 28269 Project No" 046-06-144
Hydrogen Chloride, Hydrogen Fluoride,

Chlorine And Fluorine

EPA Method

26A Analysis Analytical Report 6954

Element One, Inc. 5022-C Wrightsville

Av., Wilmington,

NC 28403 910-793-0128 FAX: 910-792-6853

ellab@el

lab.comPage 18 of 87

The following

data for Analytical

Report 6954 has been reviewed

for completeness,

accuracy, adherence to method

protocol, and compliance

with quality assurance

guidelines.

Review by:

Melissa Lawrence,

QA Officer April 5, 2006

Report Reviewed

and Finalized

By:

h, Laboratory

Director April 5, 2006

e|er•entOne 6954-Trigon M26A Report Paci<et.doc Page 2 of 16!!!!!IIIIiII SUMMARY OF RESULTS

•954-Trigon M26A P-,eport P•cl rJoc Pa.c_j,_--; 3 o• 16 Page 19 of 87Element Summary

of Analysis Summary of Method

26A Analysis Kiln R1

Kiln R2

Kiln R3 e6954-1 e6954-2

e6954-3 Total mg

Total mg

Total mg

ReagentBlank e6954-4 Page 20 of 87

Total mg HCI 7.86

6.36

5.82

< 0.06 HF 1.51

1.36

1.23

< 0.06 Ci2 0.18

0.26

0.26

< 0.03 F2 < 0.03

< 0.03

< 0.03

< 0.03

•ntOne i'•A26A Repo•t Packet.doc Page 4 of 16Page 21 of 87

ANALYTICAL NARRATIVE

ele•entOne 695.:!.-Tri!]on M26A Repod Packet.doc Page 5 of 16Element One Analytical

Narrative Page 22 of 87

Client: Trigon Element

One #: 6954 Client ID: Colby/Triangle

Brick

Analyst: MAL, JHH Method: M26 Dates Received:

03/21/06 Analytes: HCI, HF, 012 & F2

Dates Analyzed:

0/24-04/04/06 Summary of Analysis The samples

were prepared

and analyzed

according

to Method

26A protocol. The samples

were analyzed

for chloride

and fluoride

on a Metrohm

761/788

ion chromatograph system.
Detection Limits The Metrohm

reporting

limit was 0.1pg/mL

for chloride

and fluoride. Analysis QA/QC Duplicate analyses

relative

percent

difference

(RPD) and spike recovery

data are summarized in the Quality Control

section.

The hydrogen

fluoride

analysis

of the Kiln R3 sample

produced

a spike recovery

result of 87%, which is outside

of the method guidelines

of 90-110%.

Subsequent

analysis

produced

equivalent results, indicating

a matrix inference.

Therefore,

the sample

results maybe biased low for HF proportional

to the spike recovery.

All other QA/QC

data was within the criteria of the method. Additional Comments The reported

results have not been corrected

for any blank values or spike recovery values.

Due to the nature of the sample matrix, it was necessary

to analyze all samples

at a minimum

2-fold dilution to reduce interferences

and to preserve the anion column.

e•le,•e•tOne ..3f..'54-Tdgor', rvi26/-"•, Report Packet.doc ;-s:a•ie 6 of 1@