II-D-124 

ACME 

BRICK 

~'..e. I8.41 

2 June 1998 

Mr. Matt Clayton 

Midwest Research Inst. 

5520 Dillard Road, Suite 100 

Cary, NC 27511 

Dear Mr. Clayton: 

Enclosed are stack test results for our plants in Sealy, TX; 

Bennett, TX; Fort Smith, AR, and Malvern, AR (both Perla and Ouachita 

Plants). The summaries are assumed to be all that is necessary. If 

additional information is required, please notify me at 

(918) 834-0618. 

Very truly yours, 

Robert R. Simmons 

Environmental Manager 

PO Box 582590 

Tulsa, OK 74158 

Enclosures: 

cc: Mike Vickers 

ACME BRICK COMPANY ' 

A Subsidiary ol Justin IndustrJes, Inc. 

P.O. Box 1189 - Denton, Texas 76202 - TEL: 940/382-3573 - FAX: 940/383-3243 
II. SUMM RY 

~ A series of tests were performed on the Kiln exhausC and thP 

. Dryer Room exhaust at the Acme Bri k facility in Sea]y, TX on 

~ .Tune 18, 1991. ~ 

sampling was perfor.•med following pro ~cedures detailed in Tille 40: 

~ Code of Federal Regulations. t ~ 

~ Resul.ts of this test series are su ~ arized in Tables ] and 2. 

Witnessing t- he test series was t.ke vance of the Texas Air 

Control Board. 

The emission rates for Sulfur Dioxi le, HydrogQn Fluoride, and 

Particulate Matter in lbs/hr. are aE follows: 

KILN EXHAUST iTACK 

RUN POLLUTANT •MISSIO lb hr ALLOWABLE 

1 Particulate 4.107 7.3 

HF 0.0675 0.6 

S02 12.14 28.4 

2 Particulate 4.241 7.3 

HF 0.0762 0.6 

S02 12.56 28.4 

3 Particulate 4.903 7.3 

HF 0.0846 0.6 

S02 12.47 28.4 

Average Particulate 4.417 7.3 

HF 0.0761 0.6 

S02 12.37 28.4 

DRYER ROOM EXHAU STACK 

`RUN POLLUTANT EMISSION lbe/hr &LLOWABL E 

~ 1 S02 0.4261 0.6 

~ HF <0.0107 0.3 

2 S02 0.4445 0.6 

HF <0.0113 0.3 

~ 3 S02 0.5140 0.6 

~ ~ 

HF <0.0134 0.3 

verage S02 0.4615 0.6 

HF <0.0118 0.3 

2 

2- 
Exhaust Emissions Sampling 

Acme Brick, Milsap, TX 

TNRCC Permit No. 25937 

June 3 - 6, 1997 

Armstrong Environmental, Inc. 

Project W-1900-97 

Report Prepared For: 

Mr. 1Vlike Shipley 

Acme Brick 

2350 Bennett Rd. 

Milsap, TX 76066 

Report Prepared June 12, 1997 By: 

Armstrong Environmental, Inc. 

7715 Sovereign Row 

Dallas, Texas 75247 

(214) 631-0021 

3 
SUMMARY OF EMISSIONS TEST DATA 

Table : 10 

Plant : ,Acme Brick, Bennett Facility 

Location : Scrubber Exhaust, HF-HCL Train 

Operator : J. Barrera, D. Barrera 

r~i Test Date : 5-Jun-97 

Repetition : 1 2 3 

K GAS 

aiature, F 273.4 277.8 281.1 

ity, fps 35.76 36.44 36.46 

te Flow, acfm 30138.4 30713.7 30730.5 

scfm 18975.8 19608.4 19518.8 

scfh 1138550 1176506 1171131 

jre, % 10.44% 8.65% 8.71 % 

% 0.00 3.50 3.50 

1

" 17.00 17.00 17.00 

LE 

fime, hrs:min 10:43 AM 12:37 PM 2:1 5 PM 

Time, hrs:min 11:45 AM 1:45 PM 3:17 PM 

e Volume, scf 44.246 45.544 45.004 

)tic Ratio, % 102.4911 102.0938 101 .3464 

gen Fluoride 

e Weight, mg <0.044 <0.044 <0.044 

ntration, ppm <0.042 <0.041 <0.041 

ons, Ibs/hr <0.0025 <0.0025 <0.0025 

aen Chloride 

s Weight, mg 0.85 0.89 0.94 

ntration, ppm 0.813932 0.830832 0.890814 

ons, Ibs/hr 0.048115 0.050752 0.054167 

r 

i• 

.: ~ :.. 

~ . 

14 

4 
~ 

.. 

~~

. 

; 

; I. 1NTROIICTION 

A series of tests was Performed on the exhaust associated with the tunnel kiln aiid the 

dryer at the Acme Brick Quacb3ta-1?"in Malvem, AR. on October 22 & 23, 1997. 

'1lie purpose of this tt.st series was to determiue the exhaust emission rates ofparticulate, 

carbon monoxide, nit;•ogen oxides, sulfitr dioNade, VOC as C3H8, hydrogen fluoride, and 

hydrogen chIoride in I erms of Ibslhr. 

Testing followed proc -Idures detailed in Title 40: Code ofFederal Regulations (40:C1~R). 

Sannpling was perfomied by Richard Taylor and Tom Arnistrong of Armstrong 

Environxnental, Inc. using an Apex Method 5 Sasapling Train, a TherxnoEnvironmental 

- Model 10 continuous Nox a.nalyzer, a Fuji 3300 NDIR continuous CO anaIyzer, a Western 

_ Research 721 AT concinuous S02 analyzer, and a ThermoEnvironmental Model 51 

continuous FID analyzer. 

Three one hour test repetitions were performed on each source by the follo«ing schedule: 

. ; 

Kiln 10/22/97 10:40 am 2:22 pm 

Dryer 10/23/97 8:52 am 12:37 2ni 

Submitted by: 

ArmslrongEnv~

rron'PT6rva1, Inc. 

T Armstron 

f-Ir esident 

5 

I 
I I - S UNIMA R Y 

A sen'es of tests were -)erformed on the exhaust associated with the Tun el Kitu and the 

Turmel Dryer at the AI;Me Bn'ck Company QuacMta Plant in Malvem, AR on October 22 

& 23, 1997. 

SaDVag was perfora,-,d foUowing procedures detailed in Title 40: Code of Federal 

Regulations. 

Results of this test seri, ,.s are amamarized in Tables I - 2, vvith Kihi concentrations graphCd 

ui Figuies I - 3. 

Results indicate the foflowing average emission rates for the Tunnel Kiln: 

PK lb&'hr 3.17 3.17 2.97 3.10 

CO, Ibs,/hr 9.55 8.97 8.24 8.92 

Nox, IbAx 3.31 3.25 2.99 3.18 

S02, lbsAu 8.86 9.53 8.68 9.02 

VOC, lba/hr 0.847 0.660 0.666 0.724 

HeL lbs/hr 1.24 1.31 2.15 1.57 

Results indicate the foll:)wing average emission rates for the Tunnel Dryeri 

....... .. .. . .. ................ . I. ..... . 

PM, lbs/hr o.956 0.406 0.351 0.571 

CO, lbs/hr 0.139 0.0 0.011 0.05 

Nox, lb&/hr 0 0 0 0 

S02, Ibs,'hr 0 0,139 0.113 0.084 

VOC, lb&rb-r 9.844 0.535 0.519 0.633 

HIF by 13B, 1189 0.085 0.134 0.136 

0 0.083 0 0.028 

v irA..n 
Table : 1 

Plant : Acrne Brick Quachita Plant 

Location : Kiln Exhaus; 

Operator : R. Taylor, T. Arnistrong 

Test Date : 22-Oct-97 

Repetition : 1 

STACK GAS 

Temperature, F 369.2 

Velocity, fps 56,31 

Volume Flow, acfrn 29115.4 

scfrn 17549.2 

scfh 1052954 

Moisture, % 

CO2, % 

02, % 

SAMPLE 

Start Time, hrs:min 

Finish Time, hrs:min 

Sample Volume, scf 

Isokinetic Ratio, % 

6.13% 

1.50 

18.50 

10:40 AM 

11:43 AM 

41.759 

101.9477 

SUMMARY OF EMISSIONS TEST DATA 

PARTICULATE 

Front Half 

Sample Weight, mg 

Concentration, gr/scf 

Emissions, Ibs/hr 

CARBON MONOXIDE 

Concentration, ppm 

Emissions, fbs/hr 

NITROGEN OXIDE AS NO2 

Concentration, ppm 

Emissions, Ibs/hr 

SULFUR DIOXIDE 

Concentration, ppm 

Eniissions, Ibs/hr 

VOC AS C3H8 

Concentration, ppm WB 

Concentration, ppm DB 

Emissions, Ibs/hr 

f1YDROGEN CHLORfDE 

Sample Weight, mg 

Concentration, ppni 

Errnissions, Ibs/hr 

57.10 

0.021099 

3.174719 

124,71 

9.545144 

26.29 

3.305762 

50.62 

8.855749 

6.61 

7.041395 

0.846905 

22.33 

12.44348 

1.241532 

R 

367.6 

56.45 

29190.9 

17735.4 

1064123 

5.56% 

1.50 

18.50 

12:00 PM 

1 :02 PM 

41.724 

100.7929 

56.40 

0.020857 

3.171722 

116.02 

8.974217 

25.57 

3.249333 

53.91 

9.531362 

5.13 

5.432098 

0.660277 

23.38 

13.03953 

1.314802 

3 

369.0 

57.47 

29717.4 

17673.8 

1060429 

7.40 % 

1.50 

19.00 

1 :20 PM 

2:22 PM 

43.802 

106.1816 

55.80 

0.019657 

2.978741 

106.85 

8.236219 

23.63 

2.992381 

49.26 

8.679 

5.09 

5.496952 

0.66584 

40.34 

21.43119 

2.15"3448 

` 

. 1 

3 VA 
ii 

SUMMARY OF EMISSIONS TEST DATA 

Table : 2 

Plant : Acme Brick, :luachita Plant 

Location : Dryer Exhausi 

Operator : R. Taylor, T. Armstrong 

Test Date : 23-Oct-97 

Repotition : 1 2 3 

STACK GAS 

Temperature, F 86.5 89.3 91.1 

Velocity, fps 38.54 36.74 37.41 

Volunie Flow, acfm 31530.3 30057.0 30607.2 

scfm 29606.3 27880-7 28273.6 

scfh 1776377 1672840 1696419 

Moisture, % 3.15% 3.37% 3.46% 

CO2, % 0.00 0.00 0.00 

02, % 21.00 21.00 21.00 

SAMPLE 

Start Time, hrs:min 8:52 AM 10:15 AM 11 :35 AM 

Finish Time, hrs:min 9:54 AM 1 1:17 AM 12:37 PM 

Sample Volume, scf 43.423 39.966 40.489 

Isokinetic Ratio, % 99.42244 97.17101 97.0738 

PARTICULATE 

Front Half 

Sample Weight, mg 10.60 4.40 3.80 

Concsntration, gr/scf 0.003767 0.001699 0.001448 

Emissions, 1bs/hr 0.95616 0.406093 0.351068 

CARBON MONOXIDE 

Concentration, ppm 1.08 0 0-09 

Emissions, Ibs/hr 0.139454 0 0.01 1098 

NITROGEN OXIDE AS NO2 

t. Concentration, ppm 0 0 0 

Emissions, Ibs/hr 0 0 0 

r 

I SULFUR DIOXIDE 

L:- 

Concentration, ppm 0 0.5 0.4 

Emissions, Ibs/hr 0 0.138969 0.112742 

VOC AS C3H8 

Concentration, ppm WB 4.03 2.71 2.59 

Concentration, ppm DB 4.161054 2.804475 2.682739 

Emissions, Ibs/hr 0.844316 0.535886 0.51985 

HYDROGEN FLUORIDE by 13B 

Sample Weight, mg 2.10 0.92 1.45 

Concentration, ppm 2.166047 1.029055 1.596524 

Emissions, Ibs/hr 0.189789 0.08491 0.133591 

HYDROGEN CHLORIDE 

IN 

Sarnple Weight, mg 0.00 0.90 0,00 

Concentration, ppm 0 0.524027 0 

Emissions, Ibs/hr 

~ 

0 0.083064 n 

~ r 4 g 
.:~ 

rII. PROCEDURES 

1'he procedure for emissions sampling followed USEPA test methods as detailed in "I'itic 

40: Code of Federal R egulations. The following methods were used: 

Method Title 

1 Sample and Velocity Traverses for Stationary Sources 

2 Deterniination of Stack Gas Velocity and Volumetric Flow Rate (T}j)e S 

Pitot Ttibe) 

3 Gas An alysis for CO2, 02, Excess Air and Dry Molecular Weight 

4 Deternc: nation of Moisture Content in Stack Crases 

5 Determ:nation ofParticulate Emissions from Stationary Sources 

6C Determination of Sulfur Dioxide Emissions from Stationary Sources 

(Instru.cuental Analyzer Procedure) 

7E Determination of Nitrogen Oxides Emissions from Stationary Sourc.cs 

(Instrut ,ientai Analyzer Procedure) 

10 Determination of Carbon Monoxide Emissions from Stationary Sources 

25A Determ:nation of Total Gaseous Organic Conceutration using a Flauie 

Ionizati.: n Analyzer 

L 26A Determi iation of Hydrogen Halides and Halogens Emissions fronl 

Stationa.ry Sources 

02 and CO2 were detei mined using Fyrite Analyzers. 

Sampling was performe.d for PM, Hcl and I-iF on the each exhaust using a 72 inch glass 

lined heated sample prc-be with a 0.248 inch diameter stainless steel saznple probe. 

Sampling was performe:d for 2.5 minutes at each of 24 points, 12 points per traverse, 

iiiaking a total run duration of 60 nunutes. Schematics of each sampling location is show -n 

in Appendix D. Sampl(: train was configures as follows: 

r 

~ Heated quaitz fiber filter 

Impinger # 1- 0.1 N H2SO4 

impinger Q - 0.1 N H2SO4 

Inipinger #3 - 0.1 N NaOH 

Impiiiger 44 - Enipty 

~ 

I 
r ~ 

El". 

~ 

~ 

laiipinger 115 - 200 grauis silica gel 

~ ~ 

~ 

r,. 

Analysis for Hcl was p -.rformed using a Dionex 4600 IC/HI'LC, analysis for HF was 

performed using the I(:' and by analytical procedures in EPA Niethod 13B. 

Nitrogen oxides ,~vere ,ieterinined using a lbermoEnvironmental Model 10 continuous 

Nox analyzer. Analyz::r was calibrated . ~,ith 89.37 ppm and 206.1 ppm NOx in N2 EPA 

Protocol 1 gas standarils. 

Carbon Monoxide wa: determined using a Fuji N]DIR Mode13300 continuous CO 

analyzer. The analyzei• was caiibrated vvith 398 ppm, 99 ppm and 52.6 ppm CO in N2 

certified standards. 

Sulfur Dioxide was dei:ermined using a Western Research 721 AT continuous S02 

analyzer. The analyzei• was calibrated with 208 ppm and 96.38 ppm S02 in N2 EPA 

Protocol standards. 

VOC was determined 1: sing a ThermoEnvironmental Model 51 continuous FID analyzer. 

Analyzer was cah-brate:l with 100.5 ppm, 48.22 ppm and 28.14 ppm C3H8 in Au EPA 

Protocol gas standards 

CEM response was rec orded on an Advantech datalogger. A schematic of CEM 

configuration is given iii Figure 4. 

1a 

L 

O 
J 

t 

I. INTROD UCTION 

i A series of tests were performed on the tunnel kiln exhaust stack 

' at the Acme Brick Company facility in "?alvern, AR on May 29, 

1992. 

~ The purpose of this test series was to determi.ne the emission 

rate of hydrogen fluoride. 

~ ~ Testing was conducte-:i following USEPA test methods as detailed in 

Title 40: Code of Fe:ieral Regulations (40:CFR). 

~ Sampling was perfo: - med by Joe Barrera, Richard Taylor, Danny 

Barrera and Dak Nich: ~ lson Armstrong Environmental, Inc. using a 

NAPP Model 31 sampling train, modified as detailed in Method 13B. 

Present during the tre!st series was Mr. Ken Fells of ADPCE. 

I'hree one hour test repetitions were performed. 

Submitted by: 

Armst ironme ~ :al, Inc. 

om Armst ong 

President 

TA/os 
II. SUMMARY 

A series of tests we::- e conducted on the tunnel kiln exhaust stack 

at the Acme Brick 1::ompany facility in Malvern, AR on May 29, 

1992. 

Sampling was performE:d following procedures detailed in Title 40: 

Code of Federal Regu:;ations. 

Results of this test: series are summarized in Tables 1. 

Results indicate ttie-following fluoride emission rates for the 

tunnel kiln exhaust =:tack: 

Repetition 1 2 3 Avg. 

Concentration, ppm 53.68 41.22 58.81 51.23 

Emissioris, lbs/hr 3.059 2.357 3.439 2.951 

12- 
~ 

i 

~ 

~ 

i 

~ 

i 

t 

~ 

i 

s 

~ 

i 

~ 

i 

~ 

~ 

~ 

SU'•1MARY OF CMISS IONS '?'F;STI)A`l'A 

TABLE: 1 

PLANT: Acme Brick C:)mpany, Grigsby Ford Road, Malvern, AR 

LOCATION: Tunnel Ki:Ln Exhaust 

OPERATOR: D. Nichle:3on, J. Barrera 

TEST DATE: May 29, :_992 

REPETITION: 1 2 3 

STACK GAS 

Temperature, F 376.8 381.4 376.8 

Velocity, fps 62.98 63.47 64.82 

Volume Flow, acfm 31346 31590 32263 

scfm 18371 18440 18854 

scfh 1102260 1106436 1131236 

6.619 6.473 6.887 

1.0 1.5 1.0 

18.0 18.0 18.5 

9:34am 11:28am 1:07pm 

10:47am 12:34pm 2:15pm 

44.893 45.020 45.692 

141.34 101.25 100.51 

56.5 43.5 63.0 

53.68 41.22 58.81 

3.059 2.357 3.439 

t; 

r 

Moisture, % 

CO2, ~ 

02, % 

SAMPLE 

Start Time, hrs:min 

Finish Time,' hrs:miri 

Volume, scf 

Isokinetic Ratio, % 

FLUORIDES 

Sample Weight, mg 

Concentration, ppm 

Emissions, lbs/hr 

13 

3 
f 

III. PROCEDU RES 

~ The pi- ocedure for e:nissions sampling followed USEPA t.est method:; 

as detailed in Tit1e 40: Code of Federal Regulatioils. 'Phe 

following methods were used: 

~ Mettiod Title 

1 Sample and Velocity Traverses from Stationary Sources 

~ 2 Determinat:ion of Stack Gas Velocit_v and Volumetric 

Flow (Type S Pitot) 

~ 3 Gas Analys:is for CO2, 02, Excess Air :;d Dry Molecular 

Weight 

~ 4 Determinat:.on of Moisture Content ir, :ack Gas 

13B Determinat:_on of Total Fluoride Emissions from 

i Stationary Sources - Specific Ion Electrode Method 

I CO2 and 02 were det.:!rmined using a Fyrite analyzer. 

j Sampling for fluorid-:!s was conducted using a N?.PP Model 31 Method 

5 sampling train. 'I'he first and second impingers contained 200 

mis of Type II Grade water, third empty, and 200 grams of silica 

~ gel in the fourth impinger. A 47mm filter holder with a Whatman 

filter was placed bel:.ween the third and fourth impingers. 

~ Sampling was performi:!d for 2.5 minutes at each of 24 points, 12 

points per traverse• making a total run duration of 60 minutes. 

A.2473 inch ID st;:.inless steel sample probe was used with a 

~ stainless steel linec:. probe. 

/4- 
Exllaust Einissioii Sampli.ng 

Revised Test 

Acme Brick Company 

11brla,Facility 

October 12-14, 1993 

Arrnstrong Envirortrnental, Inc. 

Project W-1441-93 

Report Prepared For: 

Mf. Mike Vickers 

Acme Brick Company 

PO Box 1189 

Denton, TX 76205 t 

Report Prepared October 18, 1993 By: 

Armstrotrg Eriviroirmernial, Irrc. 

7715 Sovereign Row 

Dallas, Texas 75247 

(214) 631-0021 

! 

~ 

s 

15 
TABLE OF CONTENTS 

Page 

I. INTRODUCTION 1 

I I. S U t•1MAR Y 2- 9 

III. PROCEDURES 10 _ 71 

IV. APPENDICES 

A- CALCULATIDN SUMMARIES 12 - 53 

B- ANALYTICA.L SUMMARIES 54 _ 88 

C- STRIP CHA:.2T SUMMARIES 89 - 138 

D- FIELD DAT+t SHEETS 139 - 147 

E- EQUIPMENT CALIBRATIONS 148 - 156 

/b 
I. INTRODUCTION 

A series of tests were performed on the Rotary Kiln Exhaust, Kiln 

Exhaust anc3 the Dryer Exhaust at the Acme Brick Conipany, Perla 

facility in Malvecn, AR on October 12-14, 1993. 

The purpose of th.is test series was to determine the emission 

rates of nitrogen oxide as NO2, sulfur dioxide, carbon monoxide, 

fluoride, and VOC as C3H8 in terms of lbs/hr. 

Testing was condu.::ted following USEPA test methods as detailed in 

Title 40: Code of Federal Regulations (40:CFR). 

Sampling was performed by Joe Barrera and Jerry Salinas of Armstrong Environmen - ::al, Inc. using an Apex Method 5 sampling train, 

a TECO continuous NOx analyzer, a Fuji continuous S02 analyzer 

'- and a Horiba cont.i.nuous NDIR CO analyzer. Three one-hour repetitions were perfonited for each exhaust stack. 

Submitted by: 

Armstrong Environi;:ental, Inc. 

/ 

Jill Smith 

Environmental Spec;ialist 

~ 

Joe Barrera 

Project Manager 

E-. 

L 

{ 

~ 

i 

~ 

i 

1 l 7 
A., 

L 

II. SUMMARY 

A series of tests were conducted on the Rotary Kiln Exhaust, Kiln 

Exhattst, and the Dryer Exhaust at the Acme Brick Company facil.ity 

in Perla, AR on October 12-14, 1993. 

Sampling was perforined following procedures detailed in Title 40: 

Code of Federal Reglilations. 

Results of this tes_ series can be found in Tables ]. tJhrough 3. 

Sampling was perforiied on the exhaust stacks to determine the 

emissi.on rate of nil:rogen oxide as NO2, sulfur dioxide, carbon 

monoxide, fluori.des and VOCs as C3H8 i_n terms of lbs/hr. 

Results indicate th•:: following emission rates: 

Run # 1 2 3 Average 

ROTARY KILN EXHAUST 

Total Particulate,ll:>s/hr 3.176 1.738 2.206 2.373 

NO2, lbs/hr 3.101 2.987 3.172 3.087 

S02, lbs/hr 4.605 2.836 1.692 3.044 

CO, lbs/lir 1.095 1.160 0.984 1.080 

VOC, lbs/hr ND ND ND ND 

F-, lbs/hr 0.097 0.019 0.014 0.043 

KILN EXHAUST 

Total Particulate, '.bs/hr 2.05 1.80 1.42 1.76 

NO2, lbs/hr 1.22 5.79 1.97 2.99 

S02, lbs/hr 11.4 9.82 3.97 8.40 

CO 3 lbs/hr 6.52 6.06 5.45 6.01 

VOC, lbs/hr ND 0.32 0.57 0.30 

F-, lbs/hr 1.84 1.96 1.97 1.92 

DRYER EXHAUST 

Total Particulate, lbs/hr 2.21 1.73 2.43 2.12 

NO2, lbs/hr ND ND ND ND 

S02, lbs/hr 4.59 1.75 1.93 2.76 

€ 

2 % 
CO 3 Ibs/bz 1.00 0,99 0,98 0,99 

VDC ' lba/br 0D yJD ND 0D ` 

F-, lbo/hr 0'069 0.036 0'034 0'046 

~ 

i ^` 

Im 

o 

' 

3 / ~ 
SUiYIlV1ARY OF EMISSIONS TEST DATA 

Table : 1 

Plant : Acnne Brick, 1?erla, AR 

Location : R.otary Kiln I;:xhaust 

Operator : J. Barrera, J„Salinas 

Test Date : 13-Oct-94 

Repetition : 1 2 3 

STACB GAS 

Temperature, F 329.0 329.1 329.1 

Velocity, fps 56.27 56.63 57.28 

Volume Flow, acfm 12942.9 13024.6 13173.9 

scfm 6803.8 6855.9 6982.9 

scth 408231 411355 418972 

Moisture, % 21.57 o 21.46% 20.92% 

CO2. `yo 1.50 1.50 1.50 

02, % 15.50 16.00 15.00 

SAIVLPLE 

Start Time, hrs:mi.n 9:00 AM 10:36 AM 12:07 Pbi 

Finish Time, hrs:min 10:00 AM 11:36 AM 1:07 PM 

Sample Volume, scf 37.354 37.306 37.766 

Lsokinetic Ratio, % 106.079 105.1402 104.5016 

PARTICULATE 

Front Half 

Sample Weight, mg 121.30 65.20 85.20 

Concentration, gr/scf 0.050107 0.026967 0.03481 

Emissions, Ibs/hr 2.923096 1.585223 2.084144 

Back Half 

~ .. Sa-mpie Weight, mg 10.50 6.30 5.00 

Concentration, gr/scf 0.004337 0.002606 0.002043 

` Emissions, ibs/hr 0.25303 0.153173 0.122309 

iTotal Particulate, lbs/hr 3.176126 1.738396 2.206453 

CARBON MONOXIDE 

Concentration, ppm 36.9 38.8 32.3 

Emissions, Ibs/hr 1.094974 1.160165 0.983692 

NITROGEN OXIDE AS NO2 

Concentration, ppm 63.6 60.8 63.4 

Emissions, Ibs/hr 3.100519 2.986699 3.172091 

VOC AS C3H8 

) Concentration, ppm ND ND ND 

~ Eniissions, lbs/lu' ND ND ND 

~ 

Zo 

~~ 

4 
SUT,FUIZ DIOYIDE 

Concentration, ppm 67.9 41.5 24.3 

Eaiisaions, !bs(br 4.60542 2.836339 1.69155 

FLUOIZID E 

Sampie Weight, mg 4.01 0.78 0.57 

Concentration, ppm 4.799031 0.933462 0.6747 

Emis.sions, lbs(h.c 0.096633 0.01894 0.013943 

; 

~ 

~ . 

S 

[ 

~ 

f 

{_ 

t ~ 2j 

5 
34.14 

0.011 

1.79 

4.94 

0.002 

0.260 

2.05 

9.31 

1.22 

62.7 

11.4 

81.9 

6.52 

ND 

ND 

31.6 25.23 

0.010 0.008 

1.68 1.35 

2.25 1.3 

0.0007 0.0004 

0.119 0.070 

1.80 1.42 

42.9 14.4 

5.79 1.97 

52.3 20.9 

9.82 3.97 

73.7 65.6 

6.06 5.45 

2.48 4.34 

0.32 0.57 

SUMMARY Or EMI_SSIONS TEST DATA 

TADLE: 2 

PLANT: Acme Bric};, Perla, AR 

LOCATION: Kiln Eyhaust 

OPERATOR: J.BarrE,ra, J.Salinas 

7'EST DATE : OctobEir 12, 1993 

REPETITION: 1 2 K 

STACK GAS 

Temperature, F 350 

Velocity, fps 64.79 

Volume Flow, acfrr. 30204 

scfrr 18242 

scfh 1094527 

Moisture, % 

CO2, $ 

02, $ 

SAMPLE 

Start Time, hrs:m:in 

Finish Time, hrs:!nin 

Sample Volume, sc:` 

Isokinetic Ratio, % 

PARTICULATE 

Front Half 

Sample Weight, mg 

Concentration, gr , `scf 

Emissions, lbs/hr 

Back Half 

Sample Weight, mg 

Concentration, gr., 'scf 

Emissions, lbs/hr 

Total Particulate, lbs/hr 

P7ITROGEN OXIDES a: ;.NO2 

Concentration, pprn 

Emissa.ons, lbs/hr 

SLJLFUR DIOXIDE 

Concentration, ppr•i 

Emissions, lbs/hr 

CARBON MONOXIDE 

Concentration, ppr': 

Emissions, lbs/hr 

VOC as C31I8 

Concentration, ppn' 

Emissions, lbs/hr 

351 353 

67.07 67.57 

31266 31501 

18844 19057 

1130624 1143426 

7.04 7.13 6.46 

2 2.5 2.5 

19 19 19 

11:17am 12:56pm 2:20pm 

12:17pm 1:56pm 3:20pm 

45.941 46.995 47.122 

98.6 97.67 96.84 

1. ~~ 
23 

Table #2 Continued 

FLUORIDE 

Samp3_e Weight, mg 34.91 

Concentration, ppr, t 34.0 

Emissions, lbs/hr 1.84 

36.97 36.87 

35.2 35.0 

1.96 1.97 
75.1 

49.81 

52898 

50089 

3005345 

3.86 

0 

21 

85.3 

49.91 

53002 

49564 

2973839 

3.24 

0 

21 

6.61 9.87 

0.003 0.005 

1.31 1.97 

2.1 2.3 

0.001 0.001 

0.415 0.459 

1.73 2.43 

ND ND 

ND ND 

3.50 3.91 

1.75 1.93 

4.55 4.55 

0.99 0.98 

ND ND 

ND ND 

SUMMARY OF EMISSIONS TEST DATA 

fz 

TA33LE : 3 

PLANT: Acme Br,ick, Perla, AR 

LOCATION: Dryer Exhaust 

OPERATOR: J.Barrera, J.Salinas 

TEST DATE: October 14, 1993 

REPETITION: 1 

STACK GAS 

Temperature, F 74.3 

velocity, fps 49.68 

Volume Flow, acfm 52763 

scfm 50547 

scfh 3032841 

Moisture, g 2.89 

CO2, $ 0 

02, o 20 

SAMPLE 

Start Time, hrs : m_i.n 

Finish Time, hrs:inin 

Sample Volume, sc:'.' 

Isokinetic Ratio, $ 

PARTICULATE 

Front Half 

Sample Weight, mg 8.15 

Concentration, gr,'scf 0.004 

Emissions, lbs/hr 1.60 

Back Half 

Sample Weight, mg 3.1 

Concentration, gri'scf 0.001 

Emissions, lbs/hr 0.608 

Total Particulate, lbs/hr 2.21 

NITROGEN OXIDES a& 1102 

Concentration, ppni ND 

Emissions, ibs/hr ND 

SULFUR DIOXIDE 

Concentration, ppnt 9.11 

Emissions, lbs/hr 4.59 

CARBON MONOXIDE 

Concentration, ppn. 4.55 

Emissions, lbs/hr 1.00 

VOC as C3H8 

Concentration, ppn ND 

Emissions, lbs/hr ND 

vo 3 

9:11a.m 10:37am 12:04pm 

10:llam 11:37am 1:04pm 

34.107 33.495 32.859 

101.5 100.6 99.7 

0 Z4- 
m 

~- 

s ~ ~ 

1 ~ 

~- 

Table #3 Continued 

FLUORIDE. 

Sample Weight, mci 0.351 0.181 0.168 

Concentration, pFIm 0.460 0.242 0.229 

Emissions, lbs/hx 0.069 0.036 0.034 

LE 

~ 

r~ 

~ 

Z5 

[' v 
, + . 

II I. PROCFDURES 

The procedure fox emissions sampling followed USEPA test met}iods 

as detailed in Ti.tle 40: Code of Federal Regulations. The fol.- 

lowing methods wete used: 

Method Title 

1 Sample ,3nd Velocity Traverses from Stationary Sources 

2 Determa.ilation of Stack Gas Velocity and Volumetric 

Flow ( T,ipe S Pitot ) 

3 Gas Ana:_ysis for CO2, 02, Excess Air and Dry Molecular 

Pleight 

4 Determination of Moisture Content in Stack Gas 

5 Determi.i - tation of Particulate Emissions from 

Stationi::ry Sources 

6C Determii:ation of Sulfur Dioxide Emissions from 

Station ~ iry Sources (Instrumental Analyzer Procedure) 

7E Determiriation of Nitrous Oxides from a Stationary 

Source (Instrumental Analyzer Procedure) 

10 Determiriation of Carbon Monoxide Emissions from 

Stationz;ry Sources (Instrumental Analyzer Procedure) 

25A Determir:ation of Tota1 Gaseous Organic Concentration 

using a Flame Ionization Detector 

CO2 and 02 were determined using a Fyrite analyzer. 

Moisture and particulate on all three sources were determined 

using an Apex Metrod 5 Sampling Tra3n with 100 mis of i320 in the 

first and second impingers, third empty and 200 grams of silica 

i r gel in the fourth. The total run duration on all three sources 

was 60 minutes. 

~t Three one hour repetitions were performed on the Tunnel Kiln 

Exhaust stack usin-g a 5 foot stainless steel sampling probe with 

a 0.2463 inch ID sl:ainless steel sampling nozzle. A total of 24 

s total sampling poiits were performed at 12 points per each of two 

; ports. 

~ The Rotary Kiln exliaust stack was sampled at 25 total points, 5 

points per each of 5 sample ports using a 0.2463 inch ID nozzle 

on a 3 foot sampliitg probe. 

L Sampling on the Tuiinel Kiln Dryer exhaust was performed usiiig a 5 

foot sampling probi, with a 0.1897 inch ID nozzle. 

L 

€ 

,0 26 

f 
~ .. 

I 

L 

i 

~ 

NOx was determine!d using a Thermoelectron Chemoluminescent contiriuous P70x analyzer calibrated with 401 ppm, 99.8 ppm and 31.55 

ppm EPA Protocol NOx in N2 gas standards. 

S02 was determined using a FujS. continuous S02 analyzer calibrated with 795 ppm, 95.6 ppm, and 48.2 ppm EPA Protocol S02 in N2 

gas standards. 

CO concentrations were determined using a Horiba continuous NDIR 

CO analyzer calibrated with 405 ppm, 104 ppm and 50 ppm EPA 

Protocol CO in N2 gas standards. 

VOC was determineil using a Beckman 400A continuous FID analyzer 

calibrated with 816 ppm, 202.7 ppm and 30.4 ppm EPA Protocol C3H8 

in N2 gas standariis . 

Fluoride was dete:_mined using a Dionex HPLC. 

~~ 
STACK TEST 

EPA Methods l., 2, 3, 4 and 26A 

'..WOrganization Tested: 

Contact: 

Phone: 

Organization Performing 7'est: 

Contact: 

Phone: 

Test Date: 

Source Nos.: 

Location: 

Test Team: 

ADPC&E Representative: 

Acme Brick 

Grigsby Ford Road 

Malvern, Arkansas 72104 

Mr. Rick Hice 

(501) 332-6993 

Environmental Enterprise Group (EEG), Inc. 

1305 East Main Street 

Russellville, Arkansas 72801 

Mr. Larry Wlucher 

(501) 968-6767 

September 3 - 6. 1996 

Peria Plant: SN-13, SN-14, SN-17 and SN-18 

Ouachita Plant: SN-05 and SN-06 

Malvern, Arkansas 

Mr. Larry Whicher (EEG) 

Mr. Scott Longing (EEG) 

Mr. Joel DeYoung (EEG) 

Mr. Ken Fells 

\11. 

~ 

~ a 
SUMMARY 

A series of hydrogeri chloride i HC1) air emissions test were performed on three (3) different kiln and dryer 

systems at Acme Brick at t•Ee Perla and Ouachita facilities. These facilities are located in Perla, 

Arkansas and hlalvern, Arkan:las respectively. The tests were perfonned from Septenlber 3, 1996 throuch 

September 6, 1996. 

Testing on the sources were performed according to procedures detailed in EPA's 40: CFR Part 60 

Appendix A. 

The purpose of the tests were tci establish emission rates of HCl to submit for permit applications. 

Test results from the emissions tests are shown in the tables on the following pages. 

w 

r 

E E. 

~ 

ILI-m-13 

~ 

r: -1, 

~ 

~ 0 
SUMMARY 

~ 

~ 

~. 

Nftw 

CLIENT: Acme Brick SN-18 

SOURCE: West Gate Kiln E.x. Ds, inches = 34.0 

DATE: 09/03/96 

REPETTTION: 1 2 3 

STACR; GAS 

Temperature, F 421.0 410.0 432.0 

02, % 17:0 16.5 17.0 

CO2, % 4:0 4.0 4.0 

Moisture, % 12.88 11.97 12.30 

FLOW 

Velocity, fps 48.60' 47.88 52.87 

ACFM 18385;4 18113.0 200003 

SCFH 566,870 576,531 618,504 

SAMPLE 

Start Time 12:50pm, 3:35pm 5:20pm 

Eud Time 3:09pm 5:05pm 7:00pm . 

Volume, dscf 35:01` 35.25 38.15 

Isokenetic Ratio, % 107.3 106.2 107.1 

HCi 

Sample Weigkt, mg 13.2 13.2 0.0 

Emissions, Ibslhr 0.46 0.47 0.00 

L~ 

G` 

~. 30 
k 

~ ~ 

SUMMARY 

N..wl 

CLIENT: Acme Brick SN-17 

SOITRCE: West Gate Dr,er Ex. Ds, inches = 43.0 

DATE: 09/04/96 

REPE'T'ITION: 1 2 3 

STACK GAS 

Temperature, :F 103:0` I07.0 113.0 

02,. % 21.0 21.0 21:0' 

CO2, % 0.0 0.0 0.0 

Moisture, % 0 5.25 3.66 5.03 

FLO W 

Velocity, fps 76.82 81.24 79.28 

ACFM 46482.5 49157.0 47971`.0 

SCFH . 2,4587 534 2,627,068 21 497~985 

SA.MPLE 

Start Time 12:45pm 2:45pm 4:40pnr 

End,.T'urie 1:510m 3:52pm 5:45pm 

Volume; dscf 51::96 50:43 47.28 

Isokenetic Ratio, % 1012 93.4 92.7 

HCl 

Sample Weight, mg 0.0 0.0 0.0 

Emissions, lbs/hr 0.00 0.00 0.00 

.~ 

~ 

3l 

I 
--- --- ---- 

SUMMARY 

CLIIENT: Acme Brick SN-14 

SOURCE: East Gate Kiln ]: , x. Ds, inches = 43.0 

PATE: 9/5-6/1996 

REPETMON: 1 2 3 

STACK GAS 

Temperature, F 335-0 331.0 329.0 

02,% 18.0 18.0 17.5 

CO2, % 2.0 2.0 2.5 

Moisture, % 7.11 5.69 6.55 

FLOW 

Velocity, fps 94.48 94.27 94.12 

ACFM 57168.3 57041.3 56950.5 

SCFH 27 084.1733 2,124,981 2,106,204 

SAWLE 

Start The 9:45pm 11:45pm 1:42am 

End 'rime 10- 53prn 12.- 55am 2:5 8 am 

Volume, dscf 33.63 33.36 

Isokenetic Ratio, % 104.6 100.1 100.1 

HCI 

Sample Weight, mg 3.9 3.8 4,0 

Emissions, lb&/hr 0.51 0.52 0.55 
SUMMARY 

.~ 

N--- 

L 

CLIENT: Acme Brick SN-13 

SOURCE: East Gate Drye;: Ex. Ds, inches = 54.0 

DATE: 09/05/96 

REPETTITON: 1 2 3 

STACK GAS 

Temperature, F 110.0 112.0 114.0 

02, % 21.0 21.0 21.0 

CO2, % 0.0 0.0 0.0 

Moisture, % 4.14 2.65 3.07 

FLO W 

Velocity, fps 46:14 45.99 47.78 

ACFM 44029:5 43886.4 45594.5 

SCFH 2,315,864: 2,336,018 2,407,806 

SAMPLE 

Start Time 11:35am 1:50pm 3:45pm 

End T'une 12:48pm 2:59pm 4:53pm 

VoIume, dscf 45.49 44:84 46.29 

Isokenetic Ratio, % 98.6 96.4 96.5 

IiCI 

Sample Weight, mg 0.0 0.0 0,0 

Emissions, lbs/hr 0.00 0.00 0.00 

~ ~ 

~ 

f 33 
F 

tv 

~ 

SUMMARY 

CLIENT: Acme Bfick SN-06 

SOURCE: Quachita Mn Ex. Ds, inches = 40.0 

DATE: 09/06/96 

REPETMON: 1 2 3 

STACK GAS 

Temperature, F 388.0: 386.0 381.0 

02,% 17.5 17.5 17.5 

CO2, % 3.0 3.0 3.0 

Moisture, % 7.34 .7.99 7,34 

FLOW 

Velocity, fp s 60.90 61.96 66.72 

ACFM 31887-.2 32442:2 34934.5 

SCFH 1,095:149 1 - 108,704 1,181,620 

SAMTLE 

Stan T'une 1:07pm 3:09pm 5:14pm 

End Time 2: 1 opmz 418prn 6:24pm 

Volume,,.dsc.f 38.97 40.15 42.86 

Isokenctic Ratio, % 98.0 :99.8 99.9 

HCI 

Sample Weight, mg 6.0 6.5 7.0 

Ernissions, lbOu 0.36 0.39 0.41 

ir 5~- 
S UMMARY 

..-I 

N%.., I 

CLIENT: Acrne Brick SN-05 

SOURCE: Quachita Dryer F:x. Ds, inches = 50.0 

DATE: 09/06/96 

REPETTTION: 1 2 3 

STACK GAS 

Temperature, F 111.0 112.0 112.0 

02, % 21.0 21.0 21 _0 

CO2, % 0.0 0.0 0.0 

Moisture; % 5.00 5.29 5.19 

FLOW 

Velocity, fps 42.94 42.62 42.43 

ACFM 35130:2 34868:4 34713.0 

SCFH 1,8371 614 1,816,441 1,811,174 

SANfPLE 

Start Time 8:15pm 10:.07pm 11:45pm 

End Time 9:23.pm 11:11pm; 12:52pm 

Volume; dscf 42:90 43:30 43.54 

Isokenetic Ratio, % 100:5 102.8 103.5 

HCl 

Sample Weight, mg 0.0 5:5 0.0 

Emissions, lhs/hr 0.00 0.50 0.00 

t` 

F." 35 
METHODOLOGY 

All testing was performed as -:ietaiied in EPA 40 CFR: Part 60 Appendix A. 

Zhe following methods were used: 

Method 1 Sampl.: and Velocity Traverses for Stationary Sources 

Method 2 DeterTiunation of Stack Gas Velocity and Voiumetric Flow Rate (Type S Pztot) 

Method 3 Gas Aiialysis for Carbon Dioxide, Oxygen, Excess Air and Dry Molecular Weight 

Method 4 Detenriination of Moisture Content In Stack Gases 

Method 26A Deteniiination of Hydrogen Halide and Halogen Emissions from Stationary Sources 

, Isokinctic Method 

~ Deteimination of hydrogen chioride was completed using a CAE Method 5 sampling train. The train containe 

,. 

100 mis of .1 N Sulfuric A,::id (H2S0,) in the first two impingers, the third was empty and the fourth ha 

approximately 200 grams o:` silica gel. A 6' stainless steel lined probe was used. Sampling runs «re, 

perfomned at twelve (12) poi:nts per port for a total of 24 points. Each point was sampled for 2.5 minutf 

making run times of sixty (60) minutes. Sampling was done isokinetically by using variously sized nozzlf 

depending on the source beiria tested. 

Oxygen (02) and carbon dio>:ide (CO Z) were determined using a Fyrite analyzer. 

a~- 

L \..' 

3b 
Temperature, F 115.4 118.9 

Velocity, fps 13.78 15.75 

Vohune F1ow, acfm 5684 6496 

sc&n 4964 5680 

scth 297877 340802 

Moisture, % 4.711 4.024 

CO2, % 0 0 

02, % 21 21 

PARTICULATE SA11 ;[PLE 

Start Time, hrs:min 6:18pm 8:11pm 

Finish Time, hrs:min 7:30pm 9:15pm 

Volume, scf 33.319 38.385 

Isolemetic Ratio, % 101.8 103.7 

PARTICUI.ATE 

Sample Weight, mg 20.22 87.74 

Concentration, gr/scf 0.0094 0.0353 

Emissions, lbs/hr 0.398 1.717 

SUI,FUR DIOXIDE 

S a.mple W eight, mg 11.13 8.35 

Concentration, ppm 4.44 2.91 

Emissions, Ibs/hr 0.219 0.163 

CARBON MONOXI]:IE 

Concentration, ppm 83.0 104.9 

Emissions, lbs/hr 1.788 2.585 

NITROGEN OXIDE:;; as NO2 

Goncentration, ppm 4.99 5.03 

Emissions, lbs/hr 0.177 0.204 

VOC as C3H8 

Concentration, ppm 12.67 5.91 I Emissions, lbs/hr 0.42-9 0.229 0.230 

~ ~ L 

s 

t 

119.6 

15.47 

6383 

5610 

336582 

3.419 

0 

21 

9:34pm 

10:39pm 

37.233 

100.7 

47.71 

0.0197 

0.951 

8.35 

2.99 

0.166 

63.32 

1.542 

6.31 

0.253 

6.02 

SUNIlV[ARY OF ENQSSIONS TEST DATA 

TABLE: 7 

PLANT: Acme Brick, F't. Smith, AR 

LOCATION: Upper Dryer Exhaust 

OPERATOR: C. Jeff'et:;on, M. Peterson, R. Taylor 

TEST DATE: October 6, 1992 

REPETTTION: 1 2 3 

STACK GAS 

I 

(i 
I. INTRODUCTION 

A series of tests were I erformed on the Periodic Kiln exhaust stack and the Upper and 

Lower Dryer exhaust slacks at the Acme Brick Company facility in ~ S<< _T; _t,R on 

October 6 - 9, 1992. 

The purpose of this te!:t series was to determine exhaust emission rates of particulate, 

hydrogen fluoride, nitroi;en oxides, VOC as C3H8, carbon monoxide, and sulfur dioxidc 

in terms of lbs/hr. 

Testing followed procedures detailed in Title 40: Code of Federal Regulations (40: CFR). 

Sampling was perform,: d by Jeff Lovett, Richard Taylor, Mark Peterson and Cody 

Jefferson of Armstrong I;nvironmental, Inc. using four NAPP Modei 31 Sampling Trains, 

a ThermoEnvironmental Model 10 continuous Nox analyzer, a Beckman 400A continuous 

FID analyzer, and a Horiba Continuous CO analyzer. 

Three one hour test repetitions were performed on the upper and lower dryer exhausts 

over a six hour period o i October 6 and October 9, and 18 one hour test repetitions were 

performed on the periodic kiln exhaust over a 36 hour period October 8 and 9, 1992. 

Submitted by: 

Armstrong Environmentcxl, Inc. 

--7 7 
U. SUMMARY 

_ A series of tests were pt:rformed on the Periodic Kiln 96 exhaust stack and on the upper 

and lower dryer exhaust stacks at the Acme Brick Company facility in Ft. Sniith, AR on 

October 6 - 9, 1992 

Sampling was performed following procedures detailed in Title 40: Code of Federal 

Regulations. 

Results of this test serie:; are gammarized in Tables 1- 6 for the periodic kiln, Tables 6& 

7 for the lower and uppo:r dryer exhausts on October 6, and Tables 8& 9 for the lower 

and upper dryer exhausi s on October 9. 

Based on the results of , :his test series, the following comments can be made: 

1. Run #1 on the particidate train performed on the kiln exhaust did not meet isokinetic 

requirements. 

2. Run 914 on the Iluoride train performed on the kiln exhaust did not meet post test leak 

check. Analysis was peiformed on the samples, and the resuhs indicate numbers witl in 

the expected range. It is suspected that the leak occurred late in the rnn, or when 

removing the train from the stack. 

3. HF numbers are giv(.n in Runs 1- 9, ahhough the fluoride train was not in operation. 

These numbers were ob ,:ained analysis of the pa.rticu]ate impinger samples. 

4. The sa.mplc volume -:)n Run #10 for the fluoride train is below 30 cu. ft. The nozzle 

was changed a$er this n.in to increase the sample volume. 

~ 

~z ~ 
TABLE: 1 

PLANT: Acme Brick, :Ft. Smith, AR 

LOCATION: #6 Perio:kic Kiln 

OPERATOR: M. Petei•son, R. Taylor 

TEST DATE: 10/7/92 10/7/92 i0/7/92 10/7/92 

REPETITION: 1 2 3 4 

STACK GAS 

Temperature, F 129.4 243.8 319.5 401.4 

- Velocity, fps 25.13 23.09 23.26 24.96 

Voiume Flow, acfm 10656 9795 9867 10856 

scfm 8655 6424 5887 5619 

scfh 519322 385423 353252 337184 

Moisture, % 8.173 12.00 11.29 12.77 

CO2, % 3.0 3.5 4.0 4.0 

02, % 17.0 15.5 15.5 16.0 

Excess Air, % 412.6 263.4 269.5 312.5 

PARTICULATE SA11;~ 

Start Time, hrs:min 8:37am 10:37am 12:37pm 2:31pm 

Finish Time, hrs:min 9:42am 11:38am 1:38am 3:32pm 

Volume,scf 45.613 40.486 35.908 35.876 

Isokinetic Ratio, % 81.74 97.75 94.79 99.01 

fi 

~ 

PARTICULATE 

Sample Weight, mg 

Concentration, gr/scf 

Emissions, ibs/hr 

SULFUR DIOXIDE 

Sampie Weight, mg 

Concentration, ppm 

Emissions, lbs/hr 

231.11 109.38 30.92 148.77 

82 0.0417 0.0133 0.0640 

5.802 2.296 0.671 3.083 

96.33 108.9 133.1 235.34 

28.16 35.87 49.44 87.49 

2.418 2.286 2.887 4.877 

mofo 

~ 

~ 

CARBON MONOXII:iE 

Concentration, ppm 952.9 267.1 209.5 200.8 . 

Emissions, lbs/hr 35.79 7.446 

~i~-~ 

7.401 4.987 ~~}X, M u M 

---- 

IYITROGEN OXIDES,as NO2 

Concentration, ppm 19.06 207 17.78 

Emissions, lbs/hr 1.177 1.378

~~I 

85 0.712 

E 

--v '-n 
Tab1e H1 Continued 

VQC as C3H8 

Concentration, ppm 

Emissions, Ibs/hr 

FLUORIDE as FiF 

Sample Weight, mg 

Concentration, ppni 

Emissions, ibs/hr 

30 11.76 7.78 22.50 

; 17.90 0.515 0.312 0.862 X, M ~ M 

J 

 ~~ 

~ 

6.83 3.650 3.953 3.331 

6.366 3.83 4.670 3.946 

0.171 0.0762 0.085 0.691 

~ 

! 

L 

~ 

Ib 
~ 

~ - 

:._ 

SUMMARY OF EMLSSIONS TEST DATA 

TABLE: 2 

PLANT: Acme Brick, ::-t. Smith, AR 

LOCATION: #6 Perioc{ic Kiln 

OPERATOR: J. Lovett . C. Jefferson 

TEST DATE: 10/7/92 10/7/92 10/7/92 10/7/92 

REPETITION: 5 6 7 8 

STACK GAS 

Temperature, F 435.4 506.7 503.6 534.5 

Velocity, fps 25.56 29.40 29.75 31.23 

Volume F1ow, acfm. 10841 12469 12619 13245 

scfm 5601 6021 6283 6483 

scfh 336041 361254 376958 388948 

Moisture, % 11.75 10.75 8.279 6.413 

CO2, % 4.0 3.0 2.5 3.0 

02, % 16.0 16.0 16.5 16 

Excess Air, % 312.5 297.2 337.8 297.2 

P~IRTICULATE SAIVIPLE 

Start Time, hrs:min 4:27pm 6:31pm 8:32pm 10:36pm 

Finish Time, hrs:min 5:28pm 7:35pm 9:19pm 11:43pm 

Voluine, scf 32.537 40.437 31.445 44.238 

Isokinetic Ratio, % 90.11 104.17 103.51 105.85 

PARTICULATE 

Sample Weight, mg 48.68 28.31 93.67 130.21 

Concentration, gr/scf 0.0231 0.0108 0.0459 0.0454 

Emissions, lbs/hr 1.108 0.557 2.476 2.524 

SULFIJR DIOXIDE 

Sample Weight, mg 376.59 665.38 498.34 785.09 

Concentration, ppm 154.4 219.5 211.4 236.7 

Emissions, lbs/hr 8.576 13.11 13.17 15.22 

CARBON MONOXII!1E 

Concentration, ppm 135.9 75.2 39.59 13.84 

Emissions, lbs/hr 3.303 1.965 1.079 0.389 

NITROGEN OXIDES as NO2 

Concentration, ppm 23.40 18.8 26.8 25.6 

Emissions, lbs/hr 0.934 0.807 1.201 1.183 

tA 

! ' 

4-1 
Table #2 Contintsed 

; 

- VOC as C3H8 

Concentration, ppm 21.88 4.78 0.63 ND 

 Eniissions, lbs/hr 0.836 0.196 0.027 ND 

FLUORIDE as HF 

Sanlple Weight, mg 3.198 29.78 42.79 89.11 

Concentration, ppm 4.196 31.44 58.08 85.59 

Emissions, Ibs/hr 0.072 0.586 1.130 1.719 

)- ,,) 5 A-v6-'. 

~7 
1 

SUMMARY OF EMISSIONS TEST DATA 

TABLE:3 

PLANT: Acme Brick, Fl. Smith, AR 

LOCATION: 96 Periodic Kiln 

OPERATOR: J. Lovett, C. Jeff'erson 

TEST DATE: 10/8/92 10/8/92 10/8/92 10/8/92 

REPETTITON: 9 10 11 12 

STACK GAS 

Temperature, F 547.2 572.9 582.2 592.6 

Velocity, fps 31.21 32.07 31.06 31.26 

Volume Flow, ac&n 13238 13602 13175 13256 

scfm 6492 6515 6317 6263 

sc& 389541 390917 378996 375769 

Moisture, % 5.12 4.86 3.93 4.39 

CO2, % 3.0 2.0 1.0 1.0 

02, % 16.5 19.5 19.5 19.0 

Excess Air, % 347.2 1593 1310 896 

PARTIC'ULATE SAlYIPLE 

Start Time, hrs:min 12:28am 2:51am 4:57am 7:07am 

Fin'ssh Time, hrs:min 1:33am 3:53am 6:00am 8:10am 

Volume, scf 44.324 44.997 43.427 42.159 

Isokmetic Ratio, % 105.89 107.12 106.63 104.41 

PARTICULATE 

Sample Weight, mg 131.69 164.14 112.64 88.21 

Conceutration, gr/scf 0.0458 0.0563 0.0400 0.0323 

Emissions, lbs/hr 2.552 3.144 2.168 1.733 

SULFUR DIOXIDE 

Sample Weight, mg 793.44 774.87 637.54 425.95 

~ = Concentration, ppm 238.7 229.7 195.8 134.7 

Emissions, lbslhr 15. 3 14.84 12.27 8.37 

, ~ 

' CARBON MONOXII[E 

Concentration, ppm 5.0 ~v 

~ Emissions, Ibs/hr 0.141 ~ 

NTTROGF,N OXIDE.S as NO2 

~ Concentration, ppm 18.21 0` ~~ A V g, 

Emissions, lbs/lu 0.843 • 

L 

t 

' ' a-~ 
Table 93 Continiied 

VOC as C3H8 

Concentration, ppm r 

Emissions, Ibs/hr r, 

FLUORIDE as HF 

Sample Volume, scf 

IsolQnetic Ratio, % 

Sample Weight, mg 

Concentration, ppm 

Emissions, lbs/hr 

-- 27.002 57.108 58.434 

-- 98.97 105.4 101.8 

90.13 70.69 105.89 124.3 

86.75 111.7 79.09 90.76 

1.747 2.257 1.549 1.763 

r~ 

i a_ 

/1 // 
SUMMARY OF EMISSIONS TEST DATA 

~.. 

TABLE: 4 

PLANT: Acme Brick, Ft. Smith, AR 

LOCATION: #6 Periodi:; Kiln 

OPERATOR: M. Peterson, R. Taylor 

TEST DATE: 10/8/92 10/8/92 

REPE7TTION: 13 14 

STACK GAS 

Temperature, F 528.5 549.5 

Velocity, fps 29.45 29.37 

Volume Flow, acfm 12491 12458 

scfm 6331 6204 

scfh 379861 372275 

Moisture, % 3.659 3.347 

CO2, % 1.0 1.0 

02, % 19.0 19.0 

Excess.Air, % 896 896 

PARTICUMTE SAM:PLE 

Start T'nne, hrs:min 8:56am 12:05pm 

Finish Time, hrs:min 11:30am 1:09pm 

Volu.me, scf 42.256 41.05 

Isokinetic Ratio, % 103.5 102.6 

PARTICUI.ATE 

Sample Weight, mg 45.68 49.89 

Concentration, gr/scf 0.0167 0.0187 

Emissions, Ibs/hr 0.905 0.998 

SULF"UR DIOXIDE 

Sample Weight, mg 236.6 213.5 

Concentration, ppm 74.67 69.36 

Emissions, Ibs/hr 4.689 4.269 

FLUORIDE as HF 

Sample Vohune, scf 58.434 55.582 

Isoki.netic Ratio, % 101.8 102,5 

Sample Weight, mg 114.3 111.7 

Concentration, ppm 83.44 85.85 

Emissions, lbs/hr 1.638 1.652 

10/8/92 10/8/92 

15 16 

577.5 592.6 

32.41 32.99 

13746 13992 

6553 6574 

393227 394438 

4.898 4.907 

1.0 1.5 

19.0 18.5 

896 706 

2:30pm 4:25pm 

3:32pm 5:31pm 

44.236 44.599 

104.7 105.2 

43.68 24.81 

0.0152 0.0086 

0.856 0.484 

346.13 317.38 

104.4 94.91 

6.784 6.189 

56.349 57.557 

101.7 105.1 

150.5 57.77 

11 3 

2.316 

~4~2.8 

// ~i 
_ TABLE:5 

PLANT: Acme Brick, Fr. Smith, AR 

- LOCATION: #6 Periodic Kiln 

OPERATOR J. Lovett, C. Jefferson 

TEST DATE: 

' REPETITION: 

STACK GAS 

Temperature, F 

_ Velocity, fps 

Volume Flow, acf&n 

scfni 

sc8h 

Moisture, % 

CO2, % 

02, % 

Excess Air, % 

PARTICUI.ATE SAIVI PLE 

Start Time, hrs:win 

Finish Time, hrs:min 

Volume, scf 

IsolQnetic Ratio, % 

PARTICULATE 

Sample Weight, mg 

Concentration, gr/scf 

Emissions, Ibs/hr 

SULFiJR DIOXIDE 

Sample Weight, mg 

Concentration, ppm 

Emissions, Ibslhr 

FLUORIDE as gF 

Sample Votume, scf 

Isolcinetic Ratio, % 

Sample Weight, mg 

Concentration, ppm 

Emissions, lbs/br 

SUMMARY OF ENQSSIONS TEST DATA 

10/8/92 10/8/92 

17 18 

605.4 545.4 

32.19 31.93 

13657 13545 

6407 6764 

384408 405857 

3.919 3.463 

2.5 1.0 

17.5 18.0 

483 531 

6:45pm 8:35pm 

7:45pm 9:36pm 

43.386 44.346 

105.03 -101.69 

21.55 30.41 

0.0076 0.0106 S ~ 

0.420 0.613 

m 

y, a15 

212.5 100.2 

65.32 30.07 

4.151 2.017 

56.325 57.854 

104.7 101.8 

149.7 119.34 

113.37 88.035 

2.253 1.846 
SUMMARY OF EMISSIONS TEST DATA 

TABLE:6 

PLANT: Acme Biick, FI. Smith, AR 

LOCATION: Lower Dryer Exhaust 

OPERATOR: C. Jefferson, M. Peterson, R. Taylor 

TEST DATE: October 6, 1992 

REPETITION: 1 2 3 

STACK GAS 

Temperature, F 100.8 106.9 100.1 

- Velocity, fps 12.15 12.46 13.02 

Voluwne Flow, acfm 46670 47838 49987 

scfm 42010 42767 44891 

scffi 2520573 2565998 2693460 

Moisture, % 4.256 3.864 4.601 

CO2, % 0 0 0 

02, % 21 21 21 

PARTICULATE SANfPLE 

Start Time, hrs:mm 11:48am 1:41pm 2:40pm 

Finish Time, hrs:min 1:01pm 2:48pm 4:45pm 

Volume, scf 39.389 40.404 42.942 

Isokinetic Ratio, % 99.42 100.2 101.4 

PARTICULATE 

Sample Weight, mg 16.76 30.17 16.55 

Concentration, gr/scf 0.0066 0.0115 0.0059 

Emissions, lbs/hr 2.365 

i 

4.225 2.289 

~. SUI,FUR DIOXIDE 

Sample Weight, mg 8.35 5.57 5.57 

~ Concentration, ppm 2.83 1.84 1.73 

~ Emissions, lbs/hr 1.18 0.78 0.77 

CARBON MONOX111E 

Concentration, ppm 71.1 73.2 60.17 

Emissions, lbs/lu 12.96 13.59 11.72 

NTTROGEN OXIM";as NO2 

Concentration, ppm 2.91 2.09 5.02 

Emissions, lbs/hr 0.872 0.637 1.607 

VOC as C3H8 

Concentration, ppm 18.8 7.8 7.38 

Emissions, lbs/hr 5.386 2.275 2.259 

/l --7 
Table #6 Continued 

FLUORIDE as HF 

SamTle Volume, scf 52.329 50.401 53.391 

Sample Weight, mg 0.390 0.365 0.363 

Concentration, ppm 0.312 0.309 0.290 

Em.issions, IbsThr 0.0414 0.0410 0.0403 

i 

F~ r 

~ 

~ •a 

f1 — (c 

` 

~ 

~ 

ri m 
Table 97 Continued 

FLUORIDE as HF 

Sample Volume, scf 26.458 27.052 27.157 

Sample Weight, mg 2.47 2.78 0.207 

Concentradon, ppm 3.98 4.38 0.325 

Emissons, Ibs/hr 0.061 0.077 0.0057 

~ r-- . 

1_ 

~ 

E 

t` 14 q 
, 

1 

~ 

r - 

C7 

SUMMARY OF ENIISSIONS TFST DATA 

TABLE: 8 

PLANT: Acme Brick, Fi:. Smith, AR 

LOCATION: Lower Di,yer Exhaust 

OPERATORR C. Jeffers-in 

TEST DATE: October -;), 1992 

REPETITION: 1 2 3 

STACK GAS 

Temperature, F 99.5 105.0 110.0 

Velocity, fps 10.95 11.03 10.50 

Volume Flow, acfrn 42054 42346 40317 

scfm 37345 37552 35338 

sc$i 2240737 2253136 2120287 

Moisture, % 5.135 4.351 4.616 

CO2, % 0 0 0 

022 % 21 21 21 

FLUORIDE SAMPI.E 

Start Time, hrs:min 10:15am 11:47am 12:15pm 

Finish Time, hrs:mm 11:22am 12:52am 1:22pm 

Volume, scf 45.471 44.393 42.691 

Isokmetic Ratio, % 100.75 97.82 99.97 

ELUORIDE as HF 

Sample Weight, mg 0.254 0.261 0.410 

Concentration, ppm 0.238 0.251 0.409 

Emi.ssions, Ibs/hr 0.0276 0.0292 0.0449 

Gn 
SUMMARY OF ENIISSIONS TEST DATA 

TAB LE: 9 

PI.ANT: Acme Brick, F. Snsith, AR 

LOCATION: Upper Dr.er , Exhaust 

OPERATORR M. Peterson, R. Taylor 

TEST DATE: October 9, 1992 

REPETITION: 1 2 3 

_STACK GAS_ 

Temperature, F 117.2 119.1 129.0 

Velocity, fps 15.75 15.79 15.95 

Volume Flow, acfm 6500 6515 6582 

scfim 5638 5682 5631 

scfli 338306 340945 337889 

Moisture, % 4.452 1.356 3.833 

CO2, % 0 0 0 

02, % 21 21 21 

FLUORIDE SAMPLE 

Start Time, hrs:mm 10:50am 12:05pm 1:15pm 

Finisli Time, hrs:min 11:51am 1:06pm 2:16pm 

Volume, scf 36.060 35.976 35.658 

Isokinetac Ratio, % 101.5 100.4 100.5 

FLUORIDE as HF 

Sample Weight, mg 2.27 0.591 0.401 

Concentration, ppm 2.68 0.701 0.479 

Emissions, lbsJhr 0.047 0.012 0.0083 

41 
IlI. PR4CEDURES 

The procedure for emis:;ions sa.mpling followed USEPA test methods as detailed in Title 

40: Code of Federal Repulations. The following methods were used: 

Method Title 

1 Sample a:ld Velocity Traverses for Stationary Sources 

2 Determirtation of Stack Gas Velocity and Volumetric Flow Rate (Type S 

Pitot Tul;e) 

~ 3 Gas Anaiysis for CO2, 02, Excess Air a.nd Dry Molecular Weight 

4 Determniation of Moisture Content in Stack Gases 

5 Deternuiiation of Particulate Emissions from Stationary Sources 

6 Determitiation of Sulfur ITioxide Emissions from Stationary Sources 

7E Determuiation of Nitrogen Oxides Emissions from Stationary Sources 

(Instrummtal Analyzer Procedure) 

10 Determitiation of Carbon Monoxide Emissions from Stationary Sources 

13B Determaiation of Total Ftuoride Emissions from Stationary Sources - 

Specific I:on Electrode Method 

25A Determuiation ofTotal Gaseous Organic Concentration Using a Flamc 

Ionizatio:l Analyzer 

~ 

02 and CO2 were detei -miued using Fyrite Analyzers. 

- A TECO Model 10 conlinuous Nox analyzer was used to determine nitrogen oxides. 

Analyzer was cah'brated with 99.8 ppm and 31.5 ppm NO in N2 EPA Protocol 1 gas 

standards. 

VOC was determined u!.ing a Beckman Mode1400A continuous FID analyzer spanned 

with 902.6 ppm, 203.4 :;>pm and 29.94 ppm C3H8 in N2 EPA Protocol 1 gas standards. 

Carbon monoxide was iietermined using a Horiba PIR 2000 continuous CO analyLer 

~ spanned with 2018 pprr., 401 ppm and 99 ppm CO in N2 gas standards, certified +/- 2%. 

All analyzers were spaniied from the end of the sample probe with tedlar gas bags. A 

~ TeIlon sample line was tised. 

I 

p- i17 
Sampling for particulate was performe6 using a NAPP Model 3 Method 5 sanipling train. 

A 60 inch stainless steel heated sample probe with a 0.3733 ID sampling nozzle were used 

on the Kiln Stack, a 0.4296 inch ID nozzle on the lower dryer, and a 0.3722 inch ID 

nozzle on the top dryer. 3% H2O2 was placed in the impingers to determine Sulfur 

Dioxide. 

Sarnpling for HF was cunducted using a NAPP Model 31 Method 5 sainpling train. The 

first and second imping ~ :rs contained 200 mis of Type II water, third empty, and 200 

grams of silica gel in the fourth impinger. On October 6 a paper filter was placed between 

the third and fourth imp: ngers, later renioved due to pluggage problems. On October 9 a 

paper filter was placed iii front of the impingers. Sampling was performed using a 60 incli 

stainless steel probe witfi a 0.4896 inch sampling nozzle on the bottom dryer, a 0.312 inch 

sampling nozzle on the i:pper dryer, and a 0.4296 inch sampling nozzle on the kiln. The 

noz.zle was changed aftei -the first run on the kiln due to low sample volume. 

Analysis for HF was p4;rformed using a Dionex 4600 IC/IiPLC. Suifur dioxide was 

analyzed b% hariuin thori;i titrations of the particulate impinger solutions. 

42