AP42 Section:

Reference:

Title:

11.3

20

Building Brick And Structural Clay Wood Fired Brick Kiln, Emission Test Report, Chatham Brick And Tile Company, Gulf, NC, EMB Report 80-BRK-5, U. S. Environmental Protection Agency, Research Triangle Park, NC, October 1980.

United States Office of Air Quality EMB Report 80-ERK-5 Environmepl Fmtection manning and Standards October 1980 ABencv , Research Triangle Park NC 2771 1

Building Brick and Structural Clay Wood Fired Brick Kiln

Emission Test Report Chatham Brick and Tile Company Gulf, North Carolina

PARTICLE SIZING OF EMISSIONS FROM A SAWDUST-FIRED BRICK KILN, CHATHAM BRICK AND TILE COMPANY, GULF, NORTH CAROLINA

by

Mark D. Hansen

FINAL REPORT October 1980

EPA Contract No. 68-02-2814, Work Assignment No. 42 MRI Project No. 4468-L(42)

For

Environmental Protection Agency Emission Measurement Branch

Emission Standards and Engineering Division MD-13

Research Triangle Park, North Carolina 27711

Attn: Mr. J. E. McCarley

PREFACE

The work r e p o r t e d h e r e i n was conducted by p e r s o n n e l from Midwest - Research I n s t i t u t e (MRI), Energy and Env i ronmen ta l A n a l y s i s , I n c . (EEA),

and t h e U.S. Environmental P r o t e c t i o n Agency (EPA).

The scope of work i s s u e d under EPA C o n t r a c t No. 68-02-2814, Work A s - s ignment No. 42, was under t h e s u p e r v i s i o n o f Dr. H . Kenda l l Wilcox, MRI Manager, F i e l d Programs S e c t i o n . Mr. Mark D . Hansen s e r v e d a s F i e l d Task Leader and was a s s i s t e d i n t h e f i e l d by Mr. George R . Cobb. Messrs. Mark D . Hansen and George R . Cobb were r e s p o n s i b l e f o r summarizing t h e t e s t d a t a i n t h i s r e p o r t .

Mr. Armando Sa rasua of EEA was r e s p o n s i b l e f o r m o n i t o r i n g t h e p r o c e s s o p e r a t i o n s d u r i n g t h e t e s t i n g program. EEA p e r s o n n e l were a l s o r e s p o n s i b l e f o r w r i t i n g t h e P r o c e s s D e s c r i p t i o n and O p e r a t i o n S e c t i o n ( S e c t i o n 3) o f t h i s r e p o r t .

Members of t h e Chatham B r i c k and T i l e Company, G u l f , North C a r o l i n a , whose a s s i s t a n c e and gu idance c o n t r i b u t e d g r e a t l y t o t h e s u c c e s s o f t h e t e s t program, i n c l u d e Mr. Harold S t e w a r t , P l a n t Manager, and Mr. Leonard Gun te r , A s s i s t a n t P l a n t Manager.

Mr. Frank R . C lay , O f f i c e of Ai r Q u a l i t y P lann ing and S t a n d a r d s , E m i s - s i o n Measurement Branch, EPA, s e r v e d a s T e c h n i c a l Manager and was r e s p o n s i - b l e f o r c o o r d i n a t i n g t h e e m i s s i o n t e s t program.

S i n c e r e l y ,

Ken Wilcox, Head F i e l d Programs S e c t i o n

Approved f o r :

MIDWEST RESEARCH INSTITUTE

M . P . S c h r a g , D i r e c t o r Environmental Systems Department

October 1980

iii

CONTENTS

. Figures . Tables .

1 . 2 .

3 .

4

5

6 .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . Summary of Test Results . . . . . . . . . . . . . . . . . .

Carbon dioxide emission test data . . . . . . . . . . Particle size distribution test data . . . . . . . . .

Process Description and Operation . . . . . . . . . . . . . Process Description . . . . . . . . . . . . . . . . . Process Operations . . . . . . . . . . . . . . . . . .

Location of Sampling Points . . . . . . . . . . . . . . . . Harrop Kiln No . 2 (east) kiln exhaust stack sampling

locations . . . . . . . . . . . . . . . . . . . . . Harrop Kiln No . 1 (west) kiln exhaust stack sampling

locations . . . . . . . . . . . . . . . . . . . . . Harrop Kiln No . 1 (west) and Harrop Kiln No . 2

(east) waste heat exhaust stack sampling locations . . . . . . . . . . . . . . . . . . . . .

Sampling and Analytical Procedures . . . . . . . . . . . .

EPA Method 1 - sample and velocity traverses for stationary sources . . . . . . . . . . . . . . . . .

EPA Method 2 - determination of stack gas velocity and volumetric flow rate (type S pitot tube) . . . .

EPA Method 3 - gas analysis for carbon dioxide, oxygen, excess air, and dry molecular weight . . . .

EPA Method 4 - determination of moisture content in stack gases . . . . . . . . . . . . . . . . . . .

Particle size distribution tests . . . . . . . . . . . Appendices . . . . . . . . . . . . . . . . . . . . . . . .

Federal Register methods . . . . . . . . . . . . . . .

A . Andersen Cascade Impactor particle size

B . Carbon dioxide, oxygen, carbon monoxide, and distribution test data . . . . . . . . . . . .

nitrogen emission test data . . . . . . . . . . C . Project participants . . . . . . . . . . . . . . D . Field sampling task logs . . . . . . . . . . . . E . Sampling train calibration data . . . . . . . . . F . Scope of work . . . . . . . . . . . . . . . . . .

vi vii

1 4 4 4

10 10 12 13

13

19

19 20 20

20

20

20

21 21 24

A- 1

B- 1 c-1 D- 1 E-1 F- 1

V

FIGURES

Number

2 - 1 Andersen Mark I11 Cascade Impactor particle size results: particulate diameter versus percent weight less/greater than stated size - Harrop Kiln No. 2 (east) kiln exhaust stack, run Nos. 1 and 2 . . . . . . . . . . . . . . . . . . . 6

2 - 2 Andersen Mark I11 Cascade Impactor particle size results: differential mass-loading (dM/d Log D) versus particulate diameter - Harrop Kiln No. 2 (east) kiln exhaust stack, run Nos. 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . 9

3 - 1 Chatham Brick and Tile Company, process flow diagram. . . . . . 11

4 - 1 Overview of the Chatham Brick and Tile Company's Gulf, North Carolina, kiln building complex . . . . . . . . . . . . 14

4 - 2 Chatham Brick and Tile Company flowsheet. . . . . . . . . . . . 15

4 - 3 Schematic of sampling port locations used to sample the Harrop Kiln No. 2 (east) kiln exhaust stack . . . . . . . . . 16

4 - 4 Sampling point locations at the Harrop Kiln No. 2 (east) kiln exhaust stack. . . . . . . . . . . . . . . . . . . . . . 17

5-1 Schematic illustration of the Andersen Sampling System in sampling position. . . . . . . . . . . . . . . . . . . . . 22

vi

Number __

TABLES

1 - 1 Summary Log f o r Sampling, August 1 9 , 1980 . . . . . . . . . . . 3

2-1 Average Net Volume ( P e r c e n t ) CO , 02, C O , and N2 Determined by O r s a t A n a l y s i s $rom Harrop K i l n s Nos. 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 - 2 Andersen Mark I11 Cascade Impactor Sampling Pa rame te r s and R e s u l t s - Harrop K i l n No. 2 ( E a s t ) K i l n Exhaust S t a c k , Run No. 1 . . . . . . . . . . . . . . . . . . . . . . . 6

2-3 Andersen Mark I11 Cascade Impactor Sampling Pa rame te r s and R e s u l t s - Harrop K i l n No. 2 ( E a s t ) K i l n Exhaust S t a c k , Run No. 2 . . . . . . . . . . . . . . . . . . . . . . . 7

4-1 Harrop K i l n No. 2 ( E a s t ) K i l n Exhaust S t a c k Sampling P o i n t L o c a t i o n s . . . . . . . . . . . . . . . . . 18

v i i

S e c t i o n

SECTION 1

INTRODUCTION

of t h e C lean Air Act o f 1970 cha rg t h e A d m i n i s t r a t o r o f t h e U.S. Environmental P r o t e c t i o n Agency (EPA) w i t h -.le r e s p o n s i b i l i t y o f e s t a b l i s h i n g f e d e r a l s t a n d a r d s o f performance f o r new s t a t i o n a r y s o u r c e s which may s i g n i f i c a n t l y c o n t r i b u t e t o a i r p o l l u t i o n . When promulgated, t h e s e s t a n d a r d s o f performance f o r new s t a t i o n a r y s o u r c e s a r e t o r e f l e c t t h e deg ree of e m i s s i o n l i m i t a t i o n a c h i e v a b l e t h r o u g h a p p l i c a t i o n of t h e b e s t demons t r a t ed e m i s s i o n c o n t r o l t e c h n o l o g y .

EPA's O f f i c e of A i r Q u a l i t y P lann ing and S t a n d a r d s (OAQPS) s e l e c t e d t h e Chatham B r i c k and T i l e Company a t G u l f , North C a r o l i n a , a s a s i t e f o r an e m i s s i o n t e s t program. The t e s t program was des igned t o p r o v i d e a po r - t i o n of t h e e m i s s i o n d a t a b a s e r e q u i r e d f o r new s o u r c e performance s t a n d a r d s (NSPS) f o r t h e p r o c e s s a s s o c i a t e d w i t h t h e p r o d u c t i o n of c l a y b r i c k s . The Chatham B r i c k and T i l e Company's manufac tu r ing p l a n t p roduces c l a y b r i c k s f o r t h e b u i l d i n g b r i c k i n d u s t r y . f i r e d k i l n s (Harrop K i l n s Nos. 1 and 2 ) . The two k i l n s a r e o p e r a t e d 24-hr a day and 7 days a week. p a r a l l e l t o each o t h e r .

The c l a y b r i c k s a r e f i r e d i n two sawdust-

The two k i l n s a r e l o c a t e d i n one b u i l d i n g and a r e

The pu rpose of t h e t e s t i n g program was t o o b t a i n p a r t i c l e s i z e d i s t r i b u - t i o n d a t a and CO measurements of the k i l n e m i s s i o n s . R e s u l t s o f measurements 2 c o n t a i n e d i n t h i s r e p o r t were performed d u r i n g times o f normal o p e r a t i o n o f t h e p r o d u c t i o n p r o c e s s .

Emissions sampl ing was conducted on t h e k i l n e x h a u s t s t a c k and was te h e a t e x h a u s t s t a c k a s s o c i a t e d w i t h e a c h of t h e two Harrop K i l n s . The pro- d u c t i o n r a t e o f f i r e d b r i c k s from each of t h e two k i l n s d u r i n g sampling was approx ima te ly 5 t o n s l h r ; o r 10 t o n s l h r t o t a l .

Midwest Research I n s t i t u t e ' s (MRI's) Work Assignment No. 42 from EPA r e q u i r e d one p a r t i c l e s i z e d i s t r i b u t i o n t e s t from e a c h of t h e two k i l n ex- h a u s t s t a c k s . I n f o r m a t i o n from Chatham B r i c k and T i l e Company p e r s o n n e l p r i o r t o t h e i n i t i a t i o n o f t e s t i n g i n d i c a t e d t h a t one of t h e two k i l n s was n o t f i r e d e x c l u s i v e l y w i t h sawdus t . The Harrop K i l n No. 1 on t h e west s i d e of t h e k i l n b u i l d i n g was p e r i o d i c a l l y " f l a s h e d " w i t h n a t u r a l gas i n conjunc- t i o n w i t h t h e sawdust f u e l . The e a s t k i l n (Harrop K i l n No. 2) was e x c l u s i v e l y s a w d u s t - f i r e d d u r i n g t h e f i e l d t e s t . I n concur rence w i t h t h e EPA t e c h n i c a l manager, t h e p a r t i c l e s i z e d i s t r i b u t i o n t e s t on t h e Harrop K i l n No. 1 (west s i d e ) k i l n e x h a u s t s t a c k was o m i t t e d . I n s t e a d , two p a r t i c l e s i ze d i s t r i b u - t i o n t e s t s were conducted on t h e Harrop K i l n No. 2 ( e a s t s i d e ) k i l n e x h a u s t s t a c k . Each t e s t was conducted a t a d i f f e r e n t t r a v e r s e p o i n t l o c a t i o n .

The measurement program was conducted August 19, 1980. A copy of MRI's Work Assignmnt and Technical Directives is included in Appendix F.

The sequence of events performed during this sampling program are pre- sented in Table 1-1 (Summary Log for Sampling Matrix).

The following sections of this report cover the summary of results (Sec- tion 2 ) , process description and operation (Section 3 ) , location of sampling points (Section 41 , sampling and analytical procedures (Section 5 ) , and ap- pendices (Section 6). tory data sheets, computer reduction of test data, and results of laboratory analyses.

The appendices present copies of all field and labora-

L

- - N N

0 . . .

2 ; ; z

D

Io I

3

SECTION 2

SUMMARY OF TEST RESULTS

The r e s u l t s of t h e t e s t i n g program conducted a t Chatham Br ick and T i l e Company a r e p r e s e n t e d i n Tab les 2-1 th rough 2 - 3 .

CARBON DIOXIDE EMISSION TEST DATA

The r e s u l t s of t h e e i g h t CO emis s ion t e s t s a r e p r e s e n t e d i n Table 2-1. The p e r c e n t 0 CO, and N 2 ’ s t a c k gas a r e a l s o p re sengkd .

PARTICLE SIZE DISTRIBUTION TEST DATA

The r e s u l t s of t h e two p a r t i c l e s i z e d i s t r i b u t i o n t e s t s a t t h e Harrop

and Zry m o l e c u l a r weight ( l b / l b - m o l e ) of t h e

K i l n No. 2 ( e a s t ) k i l n e x h a u s t s t a c k have been summarized i n Tables 2-2 and 2-3 . The r e s u l t s a r e shown g r a p h i c a l l y i n F i g u r e s 2-1 and 2-2 .

.A- *- -

4

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01 Y c

03 N

N N c m N

n c c m N

c a c 0 N

N 03 0

0- N

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n m

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N

N Z N

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c n c m

0 - N m

c ? m 0

c 9 N m

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N

N m

r.

m c n n a a z z

c (D N

0 0 a

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0 0 0 0

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c a - c

0

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5

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TABLE 2 - 2 . ANDERSEN MARK 111 CASCADE IMPACTOR SAMPLING PARAMETERS AND RESULTS - HARROP KILN NO. 2 (EAST) KILN EXHAUST STACK, RUN NO. 1

I N P U T DATA FOR F ILE HUN1 TEST DATE - 8-19-80 % UATER= 7.3 PROJECT t - 4468-L42 % CARHDN D I O X I D E = 2.37 TEST S I T E - CHClTHAM HRiCt: R T I L E CO. % CARBON MONOXIDE= 0 RUN I D - ONE % OXYGEN= 17.9

ANDERSEN IMPACTOR STACK TEMPERATURE= 315.0 DEGREES F. SAMPLING TIME= 6 0 . 0 WIN. B A R . PRESSURE= 29.70 I N C H E S HG PRESSURE DROP= 0 . 0 0 I N C H E S HG S T A T I C PRESSURE= -0.34 I N C H E S 1120 SAMPLER TEMP. = 315.0 DEGREES F. N E . DELTA P= 0.5 I N C H E S HZO P A R T I C L E DENS= 1 P I T O T COEFF.= .84 METER VPL.= 38.345 C U E I C FEET METER TEMP.= 101.5 DEGREES F . DELTA H= 1.3 I N C H E S HZO PR0E:E OIA.= 0.25 I N C H E S

C A L U L ~ T E D RESULTS I

SAMPLF U0L.-DEY STD.= 35.893 CU. F T . DRY IIOLECULAK U T . = 29.10 SA'IPLE V O L . - r i i T STD.= 38.719 CU. F T . YET MOLECULAR U T . = 28.29 STACK VELOCITY= 2777.0 F T . / M I N . X I S O U N E T I C = 100.9 hOZZLE VELOCITY= 2802.7 F T . / M I t < . SAMPLING RETE-6CTUAL= 0.955 CU. FT/MIF: L D AD I N G = LOADING(DRY)=

STAGE * 0 F I N A L UT 458.64

CUk. % 14.68

F R k C T I O N 18.37 X UITHOUT F I L T E R CUM. % 18.37 UITHOUT F I L T E R

U I T H F I L T E R

J E T VEL. 74

D 5 0 S I Z E 11.57 (CM/SEC)

.004289 GRAIN/SCF UEIGHT CORRECTION= 0.080 M 2 .

.0@4626 GRAIN/SCF MASS COLLECTED=

1 2 3 4 946.67 453.96 442.09 452.85

441.55 451.42 440.57 452.39

2 . O L 2.46 1.44 0.38

16.96 22.86 13.38 3.53

33.64 56.51 69.89 73.42

23.72 2 8 . 6 0 16.74 4.42

42.09 70.70 87.44 91.86

137 229 378 673

7.21 4.87 3.31 2.11

5 453.66

453.31

0.27

2.51

75 * 93

3.14

95.00

1628

1.04

10.760 MG.

6 7 F I L T E R 950.21 437.37 570.05

449.95 437.04 567.81

0.18 0.25 2.16

1.67 2.32 20.07

77.60 79.93 100.00

2.09 2.81

97.09 100.00

2966

0.63 (MICRONS)

( G R A I N W S C F )

(MICRONS)

COUNT

DM/DLOCD 0 . 0 0 3 9 6 0.00577 0.00341 0.00078 0.00035 0.00033

GED MEAN 9.13 5.93 4.02 2.64 1.48 0.81

PARTICLE 5.40+04 1.2D+05 l.l0+05 3.6D+04 2.9D104 5.ODc04

593:

0.41 iO.41

.no055

0 . 5 1 io.51

.30+05 -

6

TABLE 2 - 3 . ANDERSEN MARK I11 CASCADE IMPACTOR SAMPLING PARAMETERS AND RESULTS - HARROP KILN NO. 2 (EAST) KILN EXHAUST STACK, RUN NO. 2

I N P U T DATA FDR F I L E RUN2

PRDJECT t - 4468-L42 X CARBDN D I O X I D E = 2.37 TEST S I T E - CHATHAM B R I C K & T I L E CD. X CAREDN MDNOXIDE= 0 RUN I D - TUD I OXYGEN= 17.9

- TEST DATE - 8-19-EO X WATER= 7.3

ANDFRSEN I M P A C T O R . ~- SlACl : TEMFECATURE= 317.0 DEGF'EES F. SAUPLING T T U i = 90.0 MIN. C A k . FRESSU+E= 29.70 INCHES r (G PRESSURE DROP= 0 . 0 0 I N C d E S HG S T A T I C FRESSLIREr: -0.34 IKCnCC H2C SAHc'LEk TEHP. = 317.0 DEGREES F . AWE. DELTA P= 0.5 IFiCHES HZO P A R T I C L E DENS= I C I T D T COEFF.= I84 METER VOL.= 58.230 CUBIC FEET METER TEMP.= 100.5 DECREES F . DELTA H= 1 . 9 INCHES H20 PROBE D I A . = 0.25 INCHES

CALCULATED RESULTS

SAUPLE UDL.-DRY STD.= 54.614 CU. F T . DRY HDLECULAR UT.= 29.10

1 2 ' 3 4 5 6 7 F I L T E R STAGE * 0 F I N A L UT 443.53 425.11 447.49 429.15 438.70 424.36 443.39 424.54 543.73

TARE UT 441.40 423.01 443.45 427.18 438.02 423.31 442.55 423.47 539.05

NET UT 2 . 0 5 2.02 3.96 1.89 0.60 0.97 0.76 0.99 4.60

FRACTIDN 11.49 11.32 22.20 10.59 3.36 5.44 4.26 5 .55 25.78

CUM. 7: 11.49 22.81 95.01 55.61 5e.97 64.41 68.67 74.22 100.06

FRACTIDN 15.48 15.26 29.91 14.28 4.53 7.33 5.74 7.48 % WITHOUT F I L T E R cun. % 15.48 30.74 60.65 74.92 79.46 86.78 92.52 1O@.OC WITHOUT F I L T E R

J E T VEL. 75 140 233 385 684 1655 3017 6033

D56 S I Z E 11.48 7.15 4*84 3.28 2 . 1 0 1.03 0.62 0.41 *:0.41

DWDLOGD 0.00258 0.00611 6.00294 0.00081 0.00082 0.00090 0,00144

GED UEAti 9.06 5.88 3.99 2.62 1.47 0 . 8 0 0.50 < 0 . 5 0

P A R T I C L E 3.5D+04 1.3D+05 9.ID+04 3.8D+04 6.9D+04 1.4Dc05 3 . 5 D + 0 5

tnc)

( U G )

t M G ) CDRRECTED

X OF TOTAL

WITH F I L T E R

(CM/SEC)

(UICRONS)

(GRAINS/SCF)

(MICRDNS)

CDUNT

7

Weight % Less Than S t a t e d S i z e

IO0 993 99.8 99 98 95 90 80 70 60 M 40 30 20 10 5 2 I 0.5 0.20.1

100

so 50

20 20

10 10

v) z z 2 2 5 5 - Lz W c W : 0 W - 1 2 2 0 I- D: 2

I I

0.5 0.5

0.2 0.2

0.1 0.1 0.102 05 I 2 s IO 20 30 40 w 60 m 80 90 95 98 99 99n99.9

Weight % G r e a t e r Than S t a t e d S i z e Andersen Mark I11 Cascade Impactor p a r t i c l e Figure 2-1.

s i z e r e s u l t s : part iculate diameter versus percent weight l e s s l g r e a t e r than s tated s i z e - Harrop Ki ln No. 2 ( e a s t ) k i l n ex - haust s tack , run Nos. 1 and 2 .

8

0.010

0.007

0.005

o.oa3

0.002

0.001

0.0007

0.0005

0.0004

0.0003

0.0002

.2 .3 .4 0.0001

. I 0

Gsomctric Meon of Particle Diameter (Microns)

Figure 2 - 2 . Andersen Mark I11 Cascade Impactor p a r t i c l e s i z e r e - s u l t s : d i f f e r e n t i a l mass- lmding (dM/d Log D) versus p a r t i c u l a t e diameter - Harrop Ki ln No. 2 ( e a s t ) k i l n exhaust s t a c k , run Nos. 1 and 2 .

9

SECTION 3

PROCESS DESCRIPTION AND OPERATION

Ch tham B r i c k and T i l e o p e r a t e s two b u i l d i n g b r i c k k Ins which were r e b u i l t i n 1951 and 1954 and have a t o t a l p r o d u c t i o n c a p a c i t y of 61,952 co red b r i c k s p e r d a y . The f i r m p roduces s t a n d a r d - s i z e co red and s o l i d b u i l d i n g b r i c k w i t h v a r i o u s s u r f a c e f i n i s h e s and t e x t u r e s a s wel l a s custom b r i c k on s p e c i a l o r d e r .

PROCESS DESCRIPTION

F i g u r e 3-1 shows t h e main s t e p s o f t h e manufac tu r ing p r o c e s s a t Chatham B r i c k and T i l e Company and a l s o i n d i c a t e s sampling l o c a t i o n s d u r i n g t h e t e s t - i n g program.

A b e l t conveyor c a r r i e s t h e c l a y from t h e s t o c k p i l e t o t h e pug m i l l where sawdust and w a t e r a r e added u n t i l the mix c o n t a i n s abou t 23% sawdust and 4% w a t e r . m i l l t o remove any a i r b u b b l e s and i s e x t r u d e d o n t o a conveyor i n a con- t i n u o u s column t h r o u g h a n a p p r o p r i a t e d i e t o o b t a i n t h e d e s i r e d s ize and shape . A c u t t i n g machine s l i c e s t h e column i n t o i n d i v i d u a l b r i c k s ; odd- s i z e d and o t h e r w i s e d e f e c t i v e b r i c k s a r e r e t u r n e d by a n o t h e r conveyor t o t h e pug m i l l f o r remixing. The u n f i r e d ( g r e e n ) b r i c k s c o n t i n u e on a con- veyor t o t h e a u t o m a t i c hacke r f o r s t a c k i n g o n t o t h e k i l n c a r s . Each k i l n c a r h o l d s 2 ,816 s t a n d a r d (3-1/2 i n . x 8 i n . x 2-1/4 i n . ) b r i c k s . The loaded k i l n c a r s a r e t h e n moved t o a h o l d i n g a r e a t o a w a i t d r y i n g and f i r i n g i n t h e k i l n .

The mix t h e n moves t h r o u g h t h e d e a e r a t i n g s e c t i o n of t h e pug

Chatham B r i c k h a s two t u n n e l k i l n s comprised o f a d r y i n g s e c t i o n , a f i r i n g s e c t i o n , and a c o o l i n g s e c t i o n . Both k i l n s a r e 111 m (364 f t ) l o n g and a r e each equipped w i t h 64 d u a l f u e l b u r n e r s which may u s e e i t h e r No. 2 f u e l o i l o r n a t u r a l g a s . I n a d d i t i o n , a pneumatic system can f e e d sawdust t o 38 a l t e r n a t i v e b u r n e r s f o r f i r i n g . Due t o r i s i n g f u e l c o s t s , t h e f i r m u s e s n a t u r a l g a s and o i l s o l e l y f o r custom f i n i s h e s on s p e c i a l o r d e r s . Sawdust i s t r u c k e d i n from l o c a l m i l l s and s t o c k p i l e d . Conveyors move t h e sawdust t o a d r y e r and t h e n t o t h e f u e l d i s t r i b u t i o n system f o r f i r i n g a t t h e r a t e of a p p r o x i m a t e l y 10 t o 13.5 tons /day p e r k i l n .

A t f u l l c a p a c i t y , a k i l n c a r i s moved i n t o t h e k i l n d r y i n g s e c t i o n e v e r y 1-1/2 h r (16 c a r s p e r day ) f o r s o l i d b r i c k and e v e r y hour and 5 min (22 c a r s p e r day ) f o r co red b r i c k . Hot a i r f o r d r y i n g i s drawn from t h e c o o l i n g s e c - t i o n of t h e k i l n and used t o r educe t h e m o i s t u r e c o n t e n t of t h e b r i c k t o less t h a n 1%. The c a r s a r e pushed from t h e d r y i n g s e c t i o n t o t h e f i r i n g s e c t i o n , where t h e b r i c k s a r e f i r e d a t a b o u t 1000°C (1830'F); t h e c a r s t hen p roceed t o t h e c o o l i n g s e c t i o n and from t h e r e t o a n a u t o m a t i c dehacke r f o r r e s t a c k i n g t h e b r i c k s i n t o m a r k e t a b l e bund les which a r e s t o r e d o u t s i d e t o a w a i t shipment .

10

Common C l a y S t o c k p i l e

4

t f

Pug Mill+ f f f * E x t r u d e r

Water

Sawdust -t

t ? Odd-size Br i ck + C u t t e r -f -+ -f +

J

Hacker (Brick S t a c k e r )

t

Holding S t a t i o n

4

C 0 2 Con ten t J

P a r t i c l e S i z e A n a l y s i s Mois tu re Con ten t

Dehacker

f

Packag ing

.I

O u t s i d e S t o r a g e

F i g u r e 3-1. Chatham B r i c k and T i l e Company, p r o c e s s flow diagram.

11

PROCESS OPERATIONS

The pu rpose o f t h i s t e s t program was t o de t e rmine t h e p a r t i c l e s ize d i s t r i b u t i o n of e m i s s i o n s from a s a w d u s t - f i r e d b u i l d i n g b r i c k k i l n .

Each k i l n h a s two s t a c k s , one e x h a u s t i n g t h e d r y i n g s e c t i o n ( n o r t h s t a c k ) , and one e x h a u s t i n g t h e f i r i n g s e c t i o n ( s o u t h s t a c k ) . An O r s a t a n a l y s i s was performed twice on each s t a c k of b o t h k i l n s . K i l n No. 1 (wes t k i l n ) was f i r e d w i t h g a s due t o a custom o r d e r r e q u i r i n g t h e b r i c k t o be manufactured a s customary 15 y e a r s ago t o o b t a i n a s p e c i a l s u r f a c e f i n i s h . K i l n No. 2 ( e a s t k i l n ) was f i r e d e x c l u s i v e l y w i t h sawdus t ; a p a r t i c l e s i z e a n a l y s i s was performed on t h e s t a c k from t h e f i r i n g s e c t i o n by means of an Andersen impac to r . I n a d d i t i o n , t h e m o i s t u r e c o n t e n t of t h e e x h a u s t gas s t r e a m from t h i s s t a c k was de t e rmined by EPA Method 4 .

The k i l n s a t Chatham B r i c k and T i l e Company a r e equipped w i t h f lowmeters t o m o n i t o r o i l and g a s f lows and thermocouples t o measure t e m p e r a t u r e . When f i r i n g w i t h sawdus t , t h e t e m p e r a t u r e r e a d i n g c o n t r o l s t h e sawdust f e e d r a t e , however, no p r o v i s i o n s e x i s t t o a c c u r a t e l y measure t h e f e e d r a t e .

On August 1 9 , 1980, p r o c e s s m o n i t o r i n g began a t 10:45 AM; t e s t i n g began s h o r t l y a f t e r 10:45 AM and was concluded a t 11:OO PM. The k i l n o p e r a t o r s r e p o r t e d t h a t t h e r e had been no p r o c e s s u p s e t s , and t h e o p e r a t i o n had been normal . During t h e day o f t h e t e s t , k i l n No. 2 had a th roughpu t of 16 c a r s , i . e . , p r o d u c t i o n o f 45,056 s t a n d a r d co red b r i c k s . T h i s reduced p r o d u c t i o n r a t e , down from 61 ,952 c o r e d b r i c k s p e r day , was due t o a slow down i n the b u i l d i n g i n d u s t r y .

The a v e r a g e t e m p e r a t u r e was 1000°C (1830'F) which i s t h e same a s d u r i n g f u l l p r o d u c t i o n . a f f e c t t h e p a r t i c l e s i z e d i s t r i b u t i o n s i n c e . k i l n t e m p e r a t u r e s , and t h u s , sawdust f i r i n g r a t e s , d u r i n g t h e t e s t i n g were i n t h e normal r a n g e s .

The reduced p r o d u c t i o n was n o t b e l i e v e d t o s i g n i f i c a n t l y

12

SECTION 4

LOCATION OF SAMPLING POINTS

T h i s s e c t i o n p r e s e n t s d e t a i l e d d e s c r i p t i o n s of t h e sampl ing l o c a t i o n s used f o r t h e measurement of CO e m i s s i o n s and p a r t i c l e s i z e d i s t r i b u t i o n . Each t e s t l o c a t i o n i s d i s c u s s e 3 s e p a r a t e l y .

A g e n e r a l i z e d overview o f t h e k i l n b u i l d i n g complex i s p r e s e n t e d i n F i g u r e 4-1. F i g u r e 4-2 p r e s e n t s a f l o w s h e e t o f t h e b r i c k making and k i l n f i r i n g p r o c e s s a t Chatham B r i c k and T i l e Company. f i r i n g zone i n t h e k i l n s i s r e c y c l e d back t o t h e b r i c k d r y i n g zone . Excess h e a t e d a i r r e c y c l e d t o t h e d r y i n g zone i s exhaus ted t o t h e atmosphere t h r o u g h a was te h e a t e x h a u s t s t a c k l o c a t e d a t t h e n o r t h end of e a c h o f t h e k i l n s . Heated a i r from t h e b r i c k f i r i n g zone t h a t i s n o t r e c y c l e d t o t h e d r y i n g zone, i s exhaus ted t o t h e atmosphere th rough a k i l n e x h a u s t s t a c k a t t h e s o u t h e r n end o f each of t h e k i l n s ( F i g u r e 4-1) . ment p r e s e n t l y e x i s t s on any o f t h e f o u r k i l n b u i l d i n g e x h a u s t s t a c k s .

Heated a i r from t h e b r i c k

No e m i s s i o n c o n t r o l equ ip -

HARROP KILN NO. 2 (EAST) KILN EXHAUST STACK SAMPLING LOCATIONS

T h i s e x h a u s t s t a c k i s r e c t a n g u l a r i n shape . A s h e e t m e t a l r e c t a n g u l a r s t a c k e x t e n s i o n w i t h p o r t s was p rov ided by Chatham B r i c k and T i l e Company f o r sampling p u r p o s e s . The s t a c k e x t e n s i o n was p l a c e d on t o p of t h e rec- t a n g u l a r b r i c k e x h a u s t s t a c k . e x h a u s t s t a c k i s p r e s e n t e d i n F i g u r e 4-3. V i e w A i s from t h e w e s t s i d e look- i n g e a s t . V i e w B i s from t h e s o u t h s i d e l o o k i n g n o r t h .

The l o c a t i o n o f t h e p o r t s used t o sample t h i s

The f i v e sampling p o r t s a r e l o c a t e d i n a 3 2 - i n . l o n g by 29 - in . wide r e c t a n g u l a r v e r t i c a l d u c t . downstream d i s t u r b a n c e ; which i s where t h e d u c t i s reduced i n s ize above t h e e x h a u s t f a n , i s 286 c m (112.75 i n . ) , o r 3 . 7 6 d u c t d i a m e t e r s . The d i s - t a n c e from t h e f i v e p o r t s t o t h e n e a r e s t upstream d i s t u r b a n c e ; which i s t h e t o p o f t h e s t a c k e x t e n s i o n , i s 66 cm (26 i n . ) , o r 0.87 d u c t d i a m e t e r s .

The d i s t a n c e from t h e f i v e p o r t s t o t h e n e a r e s t

T h i s sampling l o c a t i o n d i d n o t meet t h e "8 and 2 d i ame te r " c r i t e r i o n f o r p a r t i c u l a t e t r a v e r s e s f o r r e c t a n g u l a r s t a c k s a s o u t l i n e d i n EPA Refer- ence Method 1 ( F e d e r a l R e g i s t e r , Vol. 42, No. 160, Thursday, August 18, 1977) . S i n c e t h e s t a c k e x t e n s i o n c o n t a i n e d f i v e sampling p o r t s , n i n e sampl ing p o i n t l o c a t i o n s were chosen f o r e a c h p o r t t r a v e r s e f o r a t o t a l of 45 sampling p o i n t s . An a v e r a g e s t a c k g a s v e l o c i t y and t e m p e r a t u r e l o c a t i o n was de t e rmined by EPA Refe rence Method 2 p r o c e d u r e s f o r s e l e c t i o n of t h e p a r t i c l e s i z e d i s t r i - b u t i o n sample p o i n t l o c a t i o n . F i g u r e 4 - 4 shows t h e l o c a t i o n o f t h e t r a v e r s e p o i n t s and t h e sampling p o i n t s s e l e c t e d f o r t h e two p a r t i c l e s i z e d i s t r i b u - t i o n t e s t s . Tes t No. 1 was conducted a t t r a v e r s e p o i n t No. 2-7, p o r t No. 2 . Test No. 2 was conducted a t t r a v e r s e p o i n t No. 3-3, p o r t No. 3 . The d i s t a n c e o f t h e t r a v e r s e p o i n t s from t h e opening o f t h e sample p o r t s i s p r e s e n t e d i n Tab le 4-1.

13

3 w > 8 i-

I

c v) 3 0 I X Y

Y c v

Y v ,

- .- 2

0 0)

0 v,

e *

0 c

",

Y c

- 0

Uv,

3

14

rn Conveyor Stomge El Mixing

Extruding LJ Cutting w

Glozing - Exhourt Streom --- Fuel Streom

x : Sample Point

Stacking I , I ,Kiln

Dryer Exhaust /-I I Sawdust -- Firing K i l n Exhaust

C w l i n g 1 Packoging 0

Storage and Shipment I Figure 4 - 2 . Chatham Brick and T i l e Company

flowsheet.

15

16

- u m m @ v

N

0 z C i .i Y

e 0 L1 L1 m 2 0) I: u u m m C 0

.r( . U Y m u u m o u 3 1 0

u u .: y o m a s

X M U G ... c a ... E S m v1

d i

;f .j

W U 3 M ... I&

17

TABLE 4-1 . HARROP KILN NO. 2 (EAST) KILN EXHAUST STACK SAH- PLINC POINT LOCATIONS

Distance from outside edge of sample p o r t

P o i n t No. (4 ( i n . )

4 . 4 13.3 22.2 31.1 40 48 .9 5 7 . 8 6 6 . 1 15 .6

1 314 5 114 8 314

12 114 15 314 19 114 22 314 26 114 29 314

18

Carbon d i o x i d e e m i s s i o n t e s t s were a l s o conducted a t t h i s l o c a t i o n and were accomplished u s i n g t h e s t a c k e x t e n s i o n and sample p o r t s a s d e s c r i b e d above. No s p e c i f i c sample p o i n t l o c a t i o n o r p o r t was u t i l i z e d f o r t h e s e t e s t s .

HARROP K I L N NO. 1 (WEST) KILN EXHAUST STACK SAMPLING LOCATIONS

T h i s e x h a u s t s t a c k i s r e c t a n g u l a r i n s h a p e and i s s i m i l a r i n dimension t o t h e Harrop K i l n No. 2 ( e a s t ) k i l n e x h a u s t s t a c k . T h e r e f o r e , t h e s t a c k e x t e n s i o n used a t t h e Harrop K i l n No. 2 ( e a s t ) k i l n e x h a u s t s t a c k was a l s o u t i l i z e d a t t h i s sampling l o c a t i o n .

No p a r t i c l e s i z e d i s t r i b u t i o n t e s t s were conducted a t t h i s l o c a t i o n because t h i s k i l n (Harrop K i l n No. 1) was n o t e x c l u s i v e l y f i r e d w i t h saw- d u s t . Carbon d i o x i d e e m i s s i o n t e s t s were conducted a t t h i s l o c a t i o n u t i - l i z i n g t h e p o r t s and s t a c k e x t e n s i o n .

HARROP KILN NO. 1 (WEST) AND HARROP K I L N NO. 2 (EAST) WASTE HEAT EXHAUST STACK SAMPLING LOCATIONS

Both of t h e s e e x h a u s t s t a c k s a r e r e c t a n g u l a r i n shape . A s h e e t m e t a l r e c t a n g u l a r s t a c k e x t e n s i o n was p rov ided by Chatham B r i c k and T i l e Company f o r sampling p u r p o s e s . The s t a c k e x t e n s i o n was p l a c e d on t o p of t h e r e c - t a n g u l a r b r i c k e x h a u s t s t a c k s . T h i s s t a c k e x t e n s i o n was 40 - in . l o n g by 27-in. wide and c o n t a i n e d f o u r sample p o r t s .

The s t a c k e x t e n s i o n d i d n o t f i t p r o p e r l y on t h e Harrop K i l n No. 1 (west) waste h e a t e x h a u s t s t a c k . The s t a c k e x t e n s i o n was s l i g h t l y na r rower ( a p p r o x i - ma te ly 1 t o 2 i n . ) t h a n t h e open ing of t h e s t a c k . S i n c e t h e p r e s s u r e o f t h e s t a c k was p o s i t i v e , t h e improper f i t of t h e s t a c k e x t e n s i o n was n o t con- s i d e r e d t o h e a s i g n i f i c a n t problem f o r use i n t e s t i n g t h i s l o c a t i o n . The s t a c k e x t e n s i o n d i d f i t p r o p e r l y on t h e Harrop K i l n No. 2 ( e a s t ) w a s t e h e a t e x h a u s t s t a c k .

No p a r t i c l e s i z e d i s t r i b u t i o n t e s t s were conducted on e i t h e r o f t h e was te h e a t e x h a u s t s t a c k s . Carbon d i o x i d e e m i s s i o n t e s t s were conducted a t each of t h e waste h e a t e x h a u s t s t a c k s u t i l i z i n g t h e s t a c k e x t e n s i o n and sam- p l e p o r t s .

19

SECTION 5

SAMPLING AND ANALYTICAL PROCEDURES

This section describes the sampling equipment and analytical procedures used by MRI personnel to conduct and analyze data from the CO particle size distribution tests. test was provided by MRI unless otherwise specified.

FEDERAL REGISTER METHODS

emission and All sampling equipment use2 during the

Standard EPA methodologies as described in the Federal Register, Vol. 42 , No. 160, Part 11, Thursday, August 18, 1977, were used for Methods 1, 2 , 3 , and 4 .

EPA METHOD 1 - SAMPLE AND VELOCITY TRAVERSES FOR STATIONARY SOURCES Sample locations at the Harrop Kiln No. 2 (east) kiln exhaust stack

were determined using the procedures described in Method 1. The field data are presented in Appendix A. Method 1 determinations were not required for sampling purposes at the other kiln exhaust stack locations.

The sample port locations at the Harrop Kiln No. 2 (east) kiln exhaust stack did not meet the Method 1 criteria of eight downstream and two upstream duct diameters. The five sample ports were located 3.76 duct diameters down- stream and 0.87 duct diameters upstream from the nearest disturbances. These measurements did meet the minimum requirements of two downstream and 0 . 5 upstream duct diameters from the nearest disturbances.

EPA METHOD 2 - DETERMINATION OF STACK GAS VELOCITY AND VOLUMETRIC FLOW RATE (TYPE S PITOT TUBE)

Velocity measurements were made at the Harrop Kiln No. 2 (east) kiln exhaust stack using standard Method 2 techniques and equipment. The field data are presented in Appendix A. The calibration data for the equipment used for these measurements are presented in Appendix E. Velocity measure- ments were not conducted at the other kiln exhaust stack locations. Carbon dioxide emission sampling at these locations did not require velocity mea- surements.

EPA METHOD 3 - GAS ANALYSIS FOR CARBON DIOXIDE, OXYGEN, EXCESS AIR, AND DRY MOLECULAR WEIGHT

All CO emission measurements were made using standatd Method 3 pro- 2 cedures and equipment. The sample probe was inserted into the stack exten- sion a sufficient distance to obtain a representative sample. An Orsat analyzer was used to determine the percent CO as well as the percent 02, 2 ’

20

C O , N and d r y molcu la r we igh t o f t h e s t a c k g a s . The f i e l d d a t a a r e p r e - s e n t e 2 ' i n Appendix B .

The equipment used t o c o l l e c t and a n a l y z e t h e samples f o r t h e s e tes ts was p rov ided by t h e Emission Measurement Branch, Emission S t a n d a r d s and En- g i n e e r i n g D i v i s i o n , U.S. Environmental P r o t e c t i o n Agency, Research T r i a n g l e Pa rk , Nor th C a r o l i n a . s t e e l sample p r o b e , diaphragm pumps w i t h f low c o n t r o l and r a t e meter, i n t e - g r a t e d g a s b a g s , and a n O r s a t a n a l y z e r . w i t h f r e s h chemica l s j u s t p r i o r t o t h e f i e l d t e s t .

The equipment p r o v i d e d by EPA i n c l u d e d a s t a i n l e s s

- The O r s a t a n a l y z e r had been charged

EPA METHOD 4 - DETERMINATION OF MOISTURE CONTENT I N STACK GASES

The m o i s t u r e c o n t e n t o f t h e s t a c k g a s a t t h e Harrop K i l n No. 2 ( e a s t ) k i l n e x h a u s t s t a c k was de t e rmined u s i n g s t a n d a r d Method 4 equipment and t e c h - n iques . A m o i s t u r e d e t e r m i n a t i o n was n o t r e q u i r e d f o r sampling pu rposes a t t h e o t h e r k i l n e x h a u s t s t a c k l o c a t i o n s . The f i e l d d a t a a r e p r e s e n t e d i n Appendix A .

PARTICLE SIZE DISTRIBUTION TESTS

T e s t i n g f o r p a r t i c l e s i z e d i s t r i b u t i o n a t t h e Harrop K i l n No. 2 ( e a s t ) k i l n e x h a u s t s t a c k was done u s i n g Andersen c a s c a d e i m p a c t o r s . The Andersen Cascade Impactor (Mark 1 1 1 ) , c l a s s i f i e s p a r t i c l e s i n t o e i g h t (8) s i z e r a n g e s . F i g u r e 5-1 p r e s e n t s a s chemat i c i l l u s t r a t i o n o f t h e Andersen sampling system i n sampling p o s i t i o n . p l e r a t e i n d i c a t i n g manometer used f o r c o n t r o l l i n g t h e sampling.

Also shown i n F i g u r e 5-1 i s t h e vacuum pump and sam-

The Andersen impac to r was p r e h e a t e d i n a n oven p r i o r t o t h e sampl ing run. The impac to r and n o z z l e were p r e h e a t e d t o a t e m p e r a t u r e s u f f i c i e n t l y h i g h e r t h a n s t a c k t e m p e r a t u r e t o p r e v e n t c o n d e n s a t i o n i n t h e sample l i n e . The p r e h e a t e d impac to r was t r a n s p o r t e d from t h e oven t o t h e s t a c k wrapped i n i n s u l a t i o n m a t e r i a l .

During sampling t h e f low was a d j u s t e d t o t h e p rede te rmined flow r a t e a s i n d i c a t e d by t h e manometer m o n i t o r i n g t h e p r e s s u r e d rop a c r o s s t h e i m - p a c t o r o r i f i c e s . m i n , r e s p e c t i v e l y . A t t h e c o n c l u s i o n o f t h e sampling p e r i o d , t h e impac to r was withdrawn from t h e s t a c k w i t h a sample c o n t i n u i n g t o b e drawn u n t i l t h e n o z z l e c l e a r e d t h e sample p o r t , a t which t ime t h e vacuum pump was t u r n e d o f f . The time r e q u i r e d t o perform t h i s "sampling w h i l e withdrawing" was t y p i c a l l y n o t more t h a n 10 s e c and i s a n e g l i g i b l e p o r t i o n of t h e t o t a l sample p e r i o d . T h i s t e c h n i q u e i n s u r e s t h a t t h e impacted sample p a r t i c l e s remain i n p l a c e d u r i n g t h e wi thd rawa l p e r i o d . The f i e l d d a t a f o r t h e two t e s t runs a r e p r e s e n t e d i n Appendix A.

Sampling t ime f o r t e s t Nos. 1 and 2 were 60 min and 90

The c o l l e c t i o n s u b s t r a t e s used f o r t h e p a r t i c l e s i z e d i s t r i b u t i o n t es t s c o n s i s t e d of t h e s t a n d a r d s l o t t e d , c i r c u l a r g l a s s f i b e r f i l t e r s manufactured by t h e c a s c a d e impac to r m a n u f a c t u r e r . The f i l t e r s were tare-weighed and f ina l -we ighed i n t h e f i e l d . A p o r t a b l e vacuum d e s i c c a t i o n system was used t o c o n d i t i o n t h e f i l t e r s . A d i g i t a l e l e c t r o b a l a n c e (Cahn Model 27 ) was used t o weigh t h e f i l t e r s .

21

e c m o (I) .A

3

II I

22

Each s e t o f c o l l e c t i o n s u b s t r a t e s i n c l u d e d e i g h t s l o t t e d f i l t e r s and one u n s l o t t e d backup f i l t e r . Each f i l t e r was p l a c e d i n a s e p a r a t e , marked squa re of aluminum f o i l and f o l d e d i n h a l f f o r weighing . The p rocedures used f o r weighing t h e f i l t e r s a r e a s f o l l o w s :

1 . Complete s e t s of f i l t e r s and t h e i r numbered aluminum f o i l c o n t a i n e r were p l a c e d i n t h e vacuum d e s i c c a t i o n chamber and c o n d i t i o n e d under vacuum f o r a p e r i o d of 60 min. A mercury manometer was used t o moni tor t h e vacuum

- i n t h e chamber. A vacuum o f less t h a n 1 - i n . Hg a b s o l u t e was ach ieved .

2 . The f i l t e r s e t s were removed from t h e vacuum chamber and p l a c e d i n a n o t h e r chamber c o n t a i n i n g s i l i c a g e l t o p r e v e n t m o i s t u r e accumula t ion dur - i n g weighing.

3 . A f i l t e r and i t s numbered aluminum f o i l c o n t a i n e r was p l a c e d on t h e ba l ance pan . a weight was r eco rded . Each f i l t e r and i t s aluminum f o i l c o n t a i n e r were weighed one t ime . .

A p e r i o d of 30 s e c was mon i to red w i t h a s t o p watch b e f o r e

4 . The f i l t e r s and aluminum f o i l c o n t a i n e r s were r e t u r n e d t o t h e vac- uum d e s i c c a t i o n chamber and p l a c e d under vacuum a g a i n f o r a p e r i o d of 15 min.

5 . The f i l t e r s and aluminum f o i l c o n t a i n e r s were removed from t h e vacuum d e s i c c a t i o n chamber and r e t u r n e d t o t h e s i l i c a g e l d e s i c c a t i o n chamber. The f i l t e r s and f o i l c o n t a i n e r s were weighed a second t ime, a l l o w i n g 30 sec f o r t h e b a l a n c e t o s t a b i l i z e b e f o r e a we igh t was r eco rded .

6 . The f i l t e r s and aluminum f o i l c o n t a i n e r s were r e t u r n e d t o t h e vac- uum d e s i c c a t i o n chamber and p l a c e d under vacuum f o r a p e r i o d o f 15 min.

7 . The f i l t e r s and aluminum f o i l c o n t a i n e r s were removed from t h e vacuum chamber and p l a c e d i n t h e s i l i c a g e l d e s i c c a t i o n chamber. The f i l t e r s and aluminum f o i l c o n t a i n e r s were weighed a f i n a l , t h i r d t ime, a l l o w i n g 30 s e c f o r t h e b a l a n c e t o s t a b i l i z e b e f o r e a we igh t was r eco rded .

Upon comple t ion of each p a r t i c l e s i z e t e s t , t h e Andersen cascade impac- t o r was h e l d i n an u p r i g h t , v e r t i c a l p o s i t i o n t o p r e v e n t movement of impacted p a r t i c l e s . Both ends of t h e impactor were s e a l e d d u r i n g t r a n s p o r t a t i o n from t h e t e s t s i t e t o t h e f i e l d l a b o r a t o r y . The impac to r w a s d i sa s sembled and t h e sample recovered a c c o r d i n g t o t h e o p e r a t i o n manual p rov ided by t h e impac- t o r manufac tu re r . The r ecove red f i l t e r s t a g e s were p l a c e d i n t h e i r numbered a l u m i n u m Coi l c o n t a i n e r s .

Upon comple t ion of t h e sample r e c o v e r y , t h e f i l t e r s were f i n a l weighed i n t h e f i e l d l a b o r a t o r y a c c o r d i n g t o t h e p r o c e d u r e s p r e v i o u s l y d e s c r i b e d i n t h i s s e c t i o n . T h e r e s u l t s of t h e weighings a r e p r e s e n t e d i n Appendix A .

23

SECTION 6

APPENDICES

T h i s s e c t i o n of t h e r e p o r t p r e s e n t s c o p i e s of a l l f i e l d and l a b o r a t o r y data s h e e t s , computer r e d u c t i o n o f tes t d a t a , r e s u l t s o f l a b o r a t o r y a n a l y s e s , and sampl ing equipment c a l i b r a t i o n d a t a .

24 , .. - _.

APPENDIX A

ANDERSEN CASCADE IMPACTOR PARTICLE SIZE DISTRIBUTION TEST DATA

A-1 Andersen Cascade Impactor Particle Size Size Distribution Test Computer Data Reduction Results

A-2 Andersen Cascade Impactor Particle Size Distribution Test Field Data Sheets

A-3 Andersen Cascade Impactor Particle Size Distribution Test Laboratory Weighing Data

A- I

A - 1 Andersen Cascade Impactor Particle Size Distribution Test Computer Data Reduc- tion Results

A-2

Andersen Mark I11 Cascade Impactor Sampling Parameters and Results - Harrop Kiln No. 2 (East) K i l n Exhaust Stack, Run No. 1

A- 3

C: A L..L LJI..AlED RES ill.. TS I

SAMPLE VOL .-DRY sn. = 3F. E1Y3 C:!J, F l , DFIY Nl:!l..E~Cl.lLAk W ' T , = 29.10 SAMPLE VOLA -WET STD. = ?a. 29

LOADING= $ 0 042RY GRAIK/SCF NEIGHT CORRECTION= 0 . 0 8 0 MG. LOAOING(DRY)= .004626 G R A I N / S C F MASS COLLECTED= 10,760 MG,

STAGE # 0 F I N A L WT 458.64

( M G ) TARE WT 456.98

( M G ) NET UT 1 +58

(MG) CORRECTED

Z OF TOTFIL

WITH F I L T E R

FRACTION 14 68

CUM. X 14 + 60

FRACTION 1 A + 37 X WITHOUT F I L T E R CUH, Z 18.37 WITHOUT F I L T E R

1 446 67

444,55

2.04

18.96

33.64

23.72

42.09

2 453 + 96

451 - 4 2

2 + 46

2 2 . 8 6

Jb.51

2 El t h 0

70.70

c

3 442.09

440.57

1.44

12.38

6 9 . E19

16.74

87.44

4 452 * 85

','"" 39

0.3R

3.53

7 3 , 9 2

4.42

YI..R*

.J'_ t

F I L T E F: 6 7 453.66 450.21 437.37 570.05

453,31 449.95 437.04 567.€!1

0 .27 0.18 0.25 2 , 16

2.51 1 . 6 7 2.32 2 0 . 0 7

75.Y3 7 7 . 6 @ 79.93 1 0 0 , o ' n

c J

3.14 2.09 2.91

95,OO 9 7 . 0 V 1 0 0 . 0 0

JET VEL. 74 137 229 37H 673 162f 2966 5932 ( CM/SEC) ~~

D50 S I Z E 11.57 7 * 21. 4 6 E17 3.31 2.1.1 I. 04 e.63 0.41 .:::0,.?1 (MICRONS) . . .- -. . -.

DWDLOGD o . o o w 6 0.00577 o . o o : v t i o.00070 O , O O O ~ Z 0.00033 O , O O O ; ' J

GEO MEAN 9.13 5.93 4.02 2.h4 1.48 0.81 0.51 <:0 .51 ( G R A I N S I S C F ) -

(MICRONS) PARTICLE

COUNT

A-4

Andersen Mark I11 Cascade Impac to r Sampling Parameters and R e s u l t s - Harrop Kiln No. 2 ( E a s t ) K i l n Exhaust S t a c k , Run No. 2

A - 5

(MG)

( M G ) CORRECTEO NET UT 2 + 0 5 2 . 0 2 3 , Y 6 :I

FRACTION l l . 4 Y 1 1 . 3 7 22.20 1 G X OF TOTAL

CUM. % 1 1 . 4 9 22.81 4 5 . 0 1 5:5 WITH F I L T E R

FRACTION 1 5 . 4 8 1 5 . 2 6 2 Y . 9 1 1 4 . 2 8 *~? * 5 3 7 * 33 5 . 7 4 7 . 4 8 X WITHOUT FIL.TE:h: CUM. % 1 5 . 4 8 3 0 . 7 4 60.65 7't .YZ 7 Y . 4 6 86.78 9 2 . 5 2 100.00 N I T HOUT F I t . . T E R

JET VEL. 75 1 4 0 2 3 3 3 8 5 6 8 4 1655 3 0 1 7 6033

D 5 0 S I Z E 1 1 . 4 8 7.15 4 . 8 4 2.1.0 : l . 0 1 0 . 6 2 0 . 4 1 .::0. 4 1 (CM/SEC)

A-6

A-2 Andersen Cascade Impac to r P a r t i c l e S i z e D i s t r i b u t i o n Test F i e l d Data S h e e t s

A- 7

MIDWEST RESEARCH INSTITUTE

P a r t i c l e S iz ing - Andersen

RUN KWL

. . . Sompting Date 9-

Crew Chief

Testing Engineer 1 GPOWE Co bb n

Engr. Technician 1 -

Lab Technician 1 m * r K b. &fisefi 2 ' G c o v - q ~ - Cobh 3

Process Engineer 1 2

Other 1 n

MRI - Form PO (10/72) A - 8

I ' I ! ' ' ,

Y : - ' i , ,

............... .. i ....... )q"' f rJ

I i

I l l

SAMPLING LOCATION .K:: /- , z # L t ..- ! a f . I . i 1- ; , -- . , .- -. .. i ..* . i

INSIDE OF FAR WALL TO . . OUTSIDE OF N IPPLE. (DISTANCE A I .~ -.&/&..

. . INSIOE OF NEAR WALL TO < I I , '

PRODUCT OF

STACK I D !TO NEAREST 1 8 INCHI DISTANCE B FRACTION COLUMNS 2 AN0 3

OF STACK I D

N/A 32 " #/ + n/ft

OUTSIDE OF N IPPLE, (OISTANCE 61 - .

STACK 1.0.. iOlSTANCE A - DISTANCE B I L ! : _ . A . -2.G;- NEAREST UPSTREAM OISTURBANCE b.. NEAREST DOWNSTREAM DISTURBANCE e CALCULATOR. _ _ __--

TRAVERSE POINT LOCATION FROM OUTSIDE OF N I P P L E

(SUM OF COLUMNS 4 8 SI . _-I

J/ // ,29 f ,

i

C------L----- _._..L___

.......... .... ..............

- - L

......... ..

~ 1

7- 1

.____I

I

i I-. ._ .

! 1 ...... - I

_-.i

-I

I

,. .....

1- .... -.

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

! .........

I I ~

I. ........... -

L...~. . . . . . . . .

! ....

....... -

. , 8 . I .. , .- -.; . , .. r' -. ; . ,Li . . .

---t L __-_ u.- SCHEMATIC OF SAMPLING LOCATION

J &&

...... . . . . . . . . . . . +--

PRELIMINARY VELOCITY TRAVERSE

AVERAGE

2 L A N T C l u !!AA- I /3.*,?p+ 77& r,. DATE F - 19- PO LOCATION 1 L X . d .:..&?Sf.- STACK 1.0. TI> BAROMETRIC PRESSURE. in. Hg

I , <. , /

3 51. so STACK GAUGE PRESSURE. in. H ~ O - LJ I 7 OPERATORS / M . / J f. e. r .

5 , 4 Y 7 j'i/. 76

SCHEMATIC OF TRAVERSE POINT LAYOUT

STACK I vEiE"A"6' I TEMPERATURE I TRAVERSE I POINT

I I I I

c

a U

>- 0 a

d

U 1 ha! u

I -

&

a

€J

L a

--it- & j!d

Do

m n . ccb

0 0

T N 0

D

10

0

0

Q Q .\

a Q

A - 1 1

MIDWEST RESEARCH INSTITUTE Run Number 4, PRELIMINARY Recorded by Mo +j Date g- Jy-f L) MOISTURE DETERMINATION Assisted by ec,

Tube No.

I

Weight (Grams)

Final Initial Difference

2 GI 4, 53 a/S,3 6 *.5

- - - 7.3 % by Volume Moisture Content = IO0

PmVm I ]

(Tm+460) Wm

6. Wet/Dry Bulb Method

Total Moisture Adsorbed:

O F

O F

- Dry Bulb Temperature - Wet Bulb Temperature - -

Wa =b.5

Yo by Vc.Jme - - Moisture Content (from Ref. Table)

C. Predetermined Value

Yo Moisture Basis

MRI - Form P4 (10/72) A - 1 2

V e l o c i t y head a t sampling l o c a t i o n , i n . H20

Stack t e m p e r a t u r e a t sample p o i n t , OF

Barometr ic p r e s s u r e , i n . Hg

S t a t i c p r e s s u r e i n s t a c k , in . Hg (Pb) - + (0 .074 x gage p r e s s u r e , in. H20)

/ 0.3q

Percen t m o i s t u r e i n g a s stream b y volume

Mole f r a c t i o n , d r y g a s 100 - % H20 100

Molecular w t . d r y s t a c k g a s , l b / lb -mole (% C 0 2 x 0.44) + (% O2 x 0.32) + (% N 2 + % CO x 0.28:

Molecular u t . s t a c k g a s , l b / lb -mole (Md) (Mf) + 18(1 - Mf)

S tack v e l o c i t y , fpm

5,128.8 ( C p ) - C a l c u l a t e d nozz le d i ame te r , i n . 7

3 , where F s = 0.5 t o 0.75 f t /min

Actua l nozz le d i a m e t e r , in .

Asstuned me te r t empera tu re , OF

a so kinetic sample s t a c k c o n d i t i o n s , f t 3 /min

v s (0 .00694) (n)

3 C a l c u l a t e d m e t e r Clow r a t e , f t /min Tntt-460

Fs (Tsi460) (E) (‘lf)

A P s

Ts

Pb

P s

% H 2 0

M f

Md

El s

v s

DnC

D “ a

Tm

Fs

Fm

-45 315

7* 3

4 775

.&?3

, a 5 0

I D 5

A - 1 3

,

!-I "

.. U

Y m 0 C I

r

A - 1 4

1 >;OK 1 NETIC P E WE'U RMANC E WORKSHEET

P l a n t f L B,b.Ck''=lZ./r c? b a t e k-/'F-m Sampling Loca t ion K:/.V z 4 L s f - L S f

Tes t Number o/vC I n i t i a l 4,f

Average s t a c k t e m p e r a t u r e , O F

Meter volume ( s t d ) , 17.64(Vm) PbfA%% 'h' '''.5 ( 1 3 . b ) :?$'g45 \I,

rmei h O PH-,I.a9is

I s o k i r l e t i c e q u a t i u i i :

3 6 Tsa,g

b s t d

I Mf Mole f r a c t i o n d r y g a s , loo-% H70 7 . 100

Molecu la r w t . d r y s t a c k g a s , lb / lb- lnule (%COz x 0 .44) + (You2 x 0 . 3 2 ) + (%N2 + %CO x 0.28) fi,N Md

P s

Molecu la r w t . s t a c k g a s , lb/lb-mole (Md) (Mi) + 18( l - ~ f )

29.73 S c a t i c p r e s s u r e in s t a c k , absolutc, i n . Hg (Pb) + (0 .074 x s t a c k gage p r e s s u r e , i n HnO) -

Stack v e l o c i t y , i p m

, T o t a l sample t ime , m l r i u t c s 8

Nozz I C d i a i n e t k : r , i richc s D I1

. -

A - 1 5

-

m

u C m u 3 3 4 0 a

T t

A -

MIDWEST RESEARCH INSTITUTE

P a r t i c l e S iz ing - Andersen

- RUN :$‘,,&a

FIELD CREW

Crew Chief M < k - s cr,

Testing Engineer 1 /i7, %.$ P,L

2

Engr. Technician 1

Lab Technician

Process Engineer

Other

1 I

1 I

MRI - Form Po (10/72) A - 1 7

~ ~~~

MIDWEST RESEARCH INSTITUTE Run Number Tk,ifi PRE LlMlNARY Recorded by 4 . A

Clock

~~

Date 5 - ,?. xa MOISTURE DETERMINATION Assisted by

Dry Gas Meter

kU?IE: Same os Run No.

A. Condensor and/or Sil ica Gel Method 8arometric Pressure, P g = in. Hg

Fino1 I I I

Final

in i t ia l

Init ial Difference

I Difference 1

Total Moisture Adsorbed: Wa =

B . Wet/Dry Bulb Method

O F

"F - Dry Bulb Temperature -

Wet Bulb Temperature - -

% by Volume - Moisture Content (from Ref. Table) -

C. Predetermined Volue

Yo Moisture Basis

MRI - Form P4 (10/72) A - 1 8

ANDERSEN SAMPLING CALCULATIONS

V e l o c i t y head a t sampling l o c a t i o n , i n . H 2 0

S t ack t e m p e r a t u r e a t sample p o i n t , O F

Barometr ic p r e s s u r e , i n . Hg ~ ~~ ~ ~ ~~ ~ - 0.3 + S t a t i c pressure i n s t a c k , in. Hg

(Pb) 2 (0.074 x gage p r e s s u r e , i n . H20)

P e r c e n t m o i s t u r e i n g a s s t r eam by volume

100 - % H 2 0

100 Mole f r a c t i o n , d r y g a s

Molecular w t . d r y s t a c k g a s , l b l lb -mole (% GO2 x 0.44) + (% O 2 x 0.32) + (% N 2 + % CO x 0.28

Molecu la r w e . s t a c k g a s , l b / lb -mole (Md) (Mf) + 18(1 - M f )

S t ack v e l o c i t y , fpm

5 ,128 .8 (Cp) ( V G )C C a l c u l a t e d nozz le d i a m e t e r , i n .

Fs IVs 24 6, where F s = 0 . 5 t o 0.75 ft 3 /min

Ac tua l nozz le d i a m e t e r , i n .

;,ssitnied mecer t e m p e r a t u r e , "F

I s o k i n e t i c sample r a t e , . s t a c k c o n d i t i o n s , f t 3 / m i n

3 C a l c u l a t f d me te r f l o w r a t e , f t Imin Trrrt460

Fs (TsG60) (2) ( M f )

A-19

A P s

T s

Pb

P S

% H 2 0

M f

Md

M s

V S

DnC

D "a

Tm

FS

Fm

317 19.72

?9,73

7. 3 w

,9 6 7

b47

1( I

II N al u al E m

E U

v1 C 0 .,. y1 C 0 E .,. n I Qj '* ,

Y V Y ffi W cl

A - 2 0

ISOKINETLC PEKFtiLiANNCE WORKSHEET

Molecu la r w t . s t a c k g a s , Lb/ l b - m u l e (Md) (Mi) + l 8 ( 1 - E l l )

P l a n t C L d .I j r G Date Samp 1 i n g Locat i o n - k:/m E e L f fie5.r Test Number cy- I s o k i n e t i c e q u a t i o n :

I n i t i a l A D H

Ms

~~~~~~~~ ~

Average s t a c k t e m p e r a t u r e , O F

Mole f r a c t i o n d r y g a s , loo-% H E U

100

M i

# 92:

- Molecu la r w t . d r y s t a c k g a s , l b / l b - m u l c

(%CUz x 0.44) + (%ti2 x 0.32) + (%N, + %CU x 0.28)

S t a t i c p r e s s u r e i n s t a c k , a b s o l u t e , i n . Hg ( p b ) 5 (0.074 x s t a c k gage p r e s s u r e , i n H?U)

S tack v e l o c i t y , i p m

5,128.8 ( C p ) ( G a U g )

A - 2 1

C 0 .rl u x m n U o a .am

U a 0 u u -1 c o

m u % z 2 4 w 0 z U -1

A -22

A - 3 Andersen Cascade Impactor P a r t i c l e S i z e D i s t r i b u t i o n Test L a b o r a t o r y Weighing Data

A-23

Proiect NO. Oat0 of Work: Work Parformed by: .... ~Y.A6krLA? :. . . k -.LP-24

Title or Purpose: Continued From: .....

.................. I 15

., ~~~

. . . . . . . . . . . . . . . i . .

I ! I ‘0 i ! i I ! i i

25 1 i

I ~

I I

. . . . . . . . . . . . . . . ... .... . . . .- . . - ! . . . . . . . . . ...... . . . . . . . . . . . 3p

7-T;T-r-5LLi.-LL i--W 1 I I ’D _ U _ . . L _ . , - ii-~r‘-r37-r-~--2~l.r77-3 ._ --- -_. p -4 . . . . .

I I

Continued To: Discloxd To And Understood By Me: I i

Enlered BY: Date:

Date:. Date: . . . . .

. . i A - 2 4 i

! . _ _ _ _ -i- i _..__

2 .......... ~ --?-----..

1 30--; 6 ~-- -- .-..-_._.._._I._._ , . _____r

I ~ ! ..... 1 5 j j i i 2 0 , , ! - -i--- -.r- +-->.---..I .... L - L . - L i i ..... i !- .. J 7- ............... 1. ...... Ll-... _j .... 23 .... L-.-& ..................

1 . . . . . 1:

i ,- / .e' / 7 . . . . .

p: ,/' j d.2, 1 6

. . . . . . . . . . . .

. ~~ ~ ,.7/7& Lz:. ~ . .

i . . . 11- .e . . . . . .

. . . . . . . . . . - f

. . . 3c

. . . . . . . . . . ..... ........ ... .. ...r-. - .. - ........ . i ' : 1 5 I : 2 0 i : , 1 2 5 I 1 ' : 3 0

. . . . . 1 - .

. . . . . . . . . . . . . . .. i ... ' . . . . . . . . . . . . . . L-.?-.L ........

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5 : : ~ 10 0 . r - - - r I , Disclosed To And Understood B y Me:

j A-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Title or Purpose: f l E L / :'/< -- fl

1

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10

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j Date:

5 " l 1.0 I ' ' I ......... i .... L .... L... . a . i .... . L .... i

3 2o . ! ......... ..... 25 _, ..... ~. 30---

, . , , . . . . . . . . . . . . . . . . . . . . . . -. - .....

Work Performed by: 3 f:L? 7,N& Continued From:

1

1 . 3 ..... ........... 25 .... r . . . . ..! ... .!

I 30 . , 1 : ... 1 ..! ..... i ..... 1 . . . !...L. .

Disclosed To And Understood By Mc:

Date:

Date: A - - 5

..................... - .................. . . . . .

5

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P. 5- Discloscd To And Undcrslaod By hlc:

Dalc: . . . .

. . . . . . . . . . . .

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. - ............ . _ . . . .

Work Performed by:

Continucd From:

L/c, , ,,.,9,+i

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Work Performed ....... by: b:c,...pI( /flp . . . . . . . . . . . . . . ... 9-2 - YO . . . . . .

+ / L j - ~ { z Date of Work: ! Project NO. 1 i I Title or Purpose: j"":T Continued From: I ~ . .

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i Entered BY: i A - 2 9 D&: ~ Date: .

;-.-,- I . 1.. ........ -. ......... I ! -- L._L--'.-.... ---A --.J-.. ..:.

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j . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............_.........._._-..__..____I__.__...

0

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Continued To: Disclosed To And Underslood By Me: Enlcred BY:

Date:

- . . . . . ..............

A -30

...

Dale:

Dale:

ANDERSEN PARTICLE S I Z E ANALYSIS

T e s t NO. 0d.e F i n a l Weights Ta re Weights 9 . k - g BY Q p . Date By Date Date - ,7 - ,Y#

' T i m e , 7 3 4 Loca t ion L1., ,,,'c Loca t ion &-. . . U P .

L o c a t i o n u A. -cLJiL.l&. m o ; * / I" .6. I

T o t a l w i t h f i l t e r T o t a l w i t h o u t f i l t e r

Note: Andersen f low ra te =

a / I n c l u d e s b l a n k c o r r e c t i o n .

b / Value used f o r c a l c u l a t i o n s .

C / C a l c u l a t i o n s b a s e d on t o t a l s a m p l e w e i g h t w i t h f i l t e r are e n t e r e d on f i r s t l i n e ; c a l c u l a t i o n s based on t o t a l sample w e i g h t w i t h o u t f i l t e r a r e e n t e r e d on second l i n e f o r each s t a g e .

-

-

-

A-31

ANDERSEN PARTICLE S I Z E ANALYSIS

T o t a l w i t h f i l t e r T o t a l w i t h o u t f i l t e r

Note: Andersen f low r a t e =

a / I n c l u d e s b l ank c o r r e c t i o n .

- b /

c/

- Value used f o r c a l c u l a t i o n s .

C a l c u l a t i o n s based on t o t a l sample w e i g h t w i t h f i l t e r are e n t e r e d on f i r s t l i n e ; c a l c u l a t i o n s based on t o t a l sample weight w i t h o u t f i l t e r a r e e n t e r e d on second l i n e f o r each s t a g e .

- F

A - 3 2

A P P E N D I X B

CARBON -. . . . .. D I O X I D E , OXYGEN. CARBON ElONOXlDE, AYD N I T R O G E N F.!IISSIO~ T E S T DATA

B - 1 F i e l d D a t a Sheets

B- 1

B-1 F i e l d Data Shee ts

MIDWEST RESEARCH INSTITUTE

FIELD CREW

Crew Chief /)q, t(at45efl

Testing Engineer 1 6. Cohh *

3

Engr. Technician 1

2 3

Lab Technician 1 2 J

Process Engineer 1 2

Other 1 -

n - 3

MRI - Form PO (10/72)

L

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u 3 4

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0 i u

MIDWEST RESEARCH INSTITUTE

MRI Project Number 4468-1 Field Dates 8-JS +D g - a o c - S o

Sampling Date 8-/9- SO

FIELD CREW

Crew Chief /h . H*llSCM

Testing Engineer 1 G, CObh 2 3

Engr. Technician

Lab Technician

Process Engineer

Other

1

2 3

1

2 3

1 2

1 2

B-7

MRI - Form Po (10/72)

23

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x

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m u 5 2 2 2

ar 3 . a m

v) 5 :

u C m u 2 3 3 0 [4

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I

B-10

MIDWEST RESEARCH INSTITUTE

FIELD CREW

Crew Chief h. I4dfiSer. l

Testing Engineer 1 ( o d h 2 3

Engr. Technician 1

Lab Technician

Process Engineer

Other

2 3

1

2 3

1 2

1 2

B-11 I

MRI - Form Po (10/72)

I- w 0 c

B-12

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u

w

B-13

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0 cu

C 0 .A Y m U h o u J M

0 M & c -

a

v)

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m U C

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B-14

MIDWEST RESEARCH INSTITUTE

#&A-

FIELD CREW

Crew Chief r / l . #a uje,q

Testing Engineer 1 6. && 2 3

Engr. Technician 1

2 3

Lab Technician 1 - 3

Process Engineer 1 "

Other 1 2

MRI - Form Po (10/72) B - 1 5

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c L

i s N

0 u B-16

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C 0 .rl u m u - o u A h

0 MC4 c v

a

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C 3 a

m u C

i 0

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E-18

APPENDIX C

PROJECT PARTICIPANTS

Midwest Research I n s t i t u t e Energy and Environmental A n a l y s i s , I n c .

Chatham Brick and Tile Company U.S. Environmental P r o t e c t i o n Agency

c-1

PROJECT PARTICIPANTS

MIDWEST RESEARCH INSTITUTE

H. Kendall Wilcox, Manager, Field Programs Section - Project Manager

Mark D. Hansen, Associate Environmental Sci.entist - Project EngineerICrew Chief

George R. Cobb, Associate Chemist - Assistant Project Scientist

ENERGY AND ENVIRONMENTAL ANALYSIS, INC.

Armando Sarasua, Environmental Engineer - Process Engineer

CHATHAM BRICK AND TILE COMPANY

Harold Stewart, Plant Manager

Leonard Gunter, Assistant Plant Manager

U.S. EPA EMISSION MEASUREMENT BRANCH

Frank R. Clay, Technical Manager

c-2

APPENDIX D

FIELD SAMPLlNG TASK LOGS

D-1 Andersen Cascade Impactor P a r t i c l e S i z e D i s t r i b u t i o n Tests

D-2 Carbon Dioxide, Oxygen, Carbon Monoxide, and Ni t rogen Emission Tests

D-2-1 Harrop K i l n No. 2 ( E a s t ) K i l n Exhaust S t ack

D-2-2 Harrop K i l n No. 1 (West) K i ln Exhaust S tack

D-2-3 Harrop K i l n No. 1 (West) Waste Heat Exhaust S tack

D-2-4 Harrop Ki ln No. 2 ( E a s t ) Waste Heat Exhaust S t ack

D- I

D-1 Andersen Cascade Impactor Particle Size Distribution Tests

D-2

u x u 0.0 .a0

V

-1 G O

- 0

m o

8 u ! +

5 a & 3

m u

0 3 . a m $ 2 v)

u C m u 2 4 r3 0 14

C 0 .d u m

m u C

0 E V

T I t t

D - 3

.a 0 c I U C Y 3 3 + 0 &

a

u m .~ O h o u c l u

0 M & c v

C 3 a

VI U C

i 0

U

D-4

D-2 Carbon Dioxide, Oxygen, Carbon Monoxide, and Nitrogen Emission Tests

D-5

D-2-1 Harrop Kiln No. 2 (Eas t ) Kiln Exhaust Stack

D-6

.A 0 c I

I

d r

1 I c p t

a

.

u x U o u r l a l

Q

rl c o m u

m n

8 u u

5 z.2 d H

u c a m L

i n a c

al A . a m

m z v1

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u C m u 3 3 3 0 a

C 3 a

m u C

i 0

V

D-7

D-2-2 Harrop K i l n No. 1 (West) K i l n Exhaust Stack

D-8

I

C 0 .3 u x m n

c;

u C I m r

& C 3 ,

U C m U 3 3 3 0

3 a m v)

E

C 3 a

u1 U C

i 0 V

D - 9

D-2-3 Harrop Kiln No. 1 (West) Waste Heat Exhaust Stack

D-10

C 0 .3 u x m o u o v a w

rn -1 c o

m u - w

8 u u

ts 3

0 z U 0

u w c w '1

Lox% m u 0

- m u

2 u e 4 M o w o m

m

u E m u 3 3 3 0 &

C 0 .?I u m u - o u - 1 u

0

25 .3 4

C

2

v1 U C

i 0

V

D-11

D-2-4 Harrop Kiln No. 2 (East) Waste Heat Exhaust Stack

D-12

u C m u 2 4 4 0 Cb

C 2 a

VI u C

0 V

D-13

APPENDIX E

SAMPLING TRAIN CALIBRATION DATA

E-1 Sample O r i f i c e C a l i b r a t i o n

E-1-1 P r e t e s t C a l i b r a t i o n

E-1-2 P o s t t e s t C a l i b r a t i o n

E-2 Nozzle Measurements

E-3 P i t o t Tube C a l i b r a t i o n

E - 1

E-1 Sample Orifice C a l i b r a t i o n

E-2

E-1-1 P r e t e s t C a l i b r a t i o n

E-3

Console No. 6 Operator R c s

BAROMETRIC PRESSURE 2% 06 7

- CFd M S Inches H20 T i m e Man. I

CFW 0 1

I

I F i n i s h 1 2

I o

S t a r t To t a l

I A

F i n i s h S t a r t r T o t a l

3 4 5

1 2 3 4 5

792.1s S- - I .

F i n i s h S t a r t T o t a l

4 6 8 10

I Averages I

I I

ITd

I1

OTd

E

72. 73 7 Y 75- 76 77 p 3

1.-

Tw

I

I 70.7 70,7

70’7 1 70.7

0 I

Page 1 of 2 pages

RAC CALIBUTION AND CHECKLIST

Date ,c -/2-- go Console NO. 6 Operator F- Cs

Pump o i l B k Clcan quick connects k- b b o m e t e r s oCecr A crt, o t i D n t e s t meter Lectk chr& 0l .C Thermometers fa [;h,,.f e ,4 Telephones Lights Sk E l e c t r i c a l check - Amphenol R /< ll0 v r e c e p t . Variac ok Vacuum gauge Check Thermocouple Switch ol< Leak check a t 27 i n . Remarks Ss>-'' I/QCcu- ri M C L Y

pump C/eqepA

Valves O K

Buz z e r m c ; Timer and Timer Gears

C m f CFM 2 ? P O - leakage = Less than 0 o o 2

R A W CALIBfiATION DATA t = t ime minutes ph = barometr ic p r e s s u r e CFw = volume wet t e s t meter CFd = volume (RAC) bj t e s t meter

b Time = temperature (OF) wet t e s t

meter I T d = i n l e t temperature ( O F ) d ry

OTd = o u t l e t t empera tu re ( O F ) dry t e s t meter

t e s t meter

E - 6

MRI - Form c1

I

STACK TEMPERATURE SENSOR CALIBRATION DATA FORM

Date s- /J--8d Thermocouple number &,a/, % z

i n . Hg OC Barometric pressure ------. Ambient temperature

Cal ibra tor f: ( s Reference: mercury-in-glass yc 3 -

Reference poin ta

number

Odt le t

b Source ( spec i fy )

' I

o the r

Reference thermometer temperature, e/=

Thermocouple potentiometer

aEvery 3OoC (50°F) f o r each re ference p o i n t . bType of c a l i b r a t i o n system used.

Temperature, d i f fe rence ,

%

*

_(ref temp, O c + 273) - ( t e s t thermom temp, " C + 27311 1oo<1.5%. ref temp, ' C + 273 -

Quali ty Assurance Handbook M2-2.10 E - 7

E-1-2 P o s t t e s t C a l i b r a t i o n

E-8

- .- . . . .

5 Lo .s +

3 Y -

C e

N I E z

0 ro u i n u '

rl c

3 a

>

0 n i Lo

21; 4

+ Ti E 4

n a

3 >

i 0 .

Y

L

0

u c D 3 0.

2 - Y

x 1 I

1 / Q

m 5 I 4 Y E

= o 5 0 c I.

Y O m u O W i z

2 %

u n w Y

x Y 3

0 Y

Y W u i( i Y Ol 3 Y

Y 3 3

Y w 1J Y

X ' ; ,- ~ - -, L:

t. v1 w E, E, v)

0 ;s. I1

L 5 : I

U P 0 " I

E-2 Nozzle Measurements

E-10

We were unable to locate recent calibration data for the straight sam- pling nozzles to be used for this work assignment (EPA Contract No. 68-02- 2814, Work Assignment No. 4 2 , MRI Project No. 4 4 6 8 - L ( 4 2 ) ) prior to the field test at Chatham Brick and Tile Company, Gulf, North Carolina, (August 18 to 2 0 , 1 9 8 0 ) . All nozzles to be used during this work assignment were checked for damage at MRI prior to the field test. taken in the field and were used to determine the nozzle diameter needed for the calculated nozzle size required for testing purposes.

zles used for this work assignment:

Approximate measurements were

Subsequent post- - test measurements at MRI yielded the following measurements of the two noz-

Particle Size Nozzle Test No. No. Diameter 1 Diameter 2 Diameter 3 Average

1 A1 0 . 2 4 4 in. 0 .244 i n . 0 .244 in. 0 .244 in. 2 A 2 0 .246 in. 0 . 2 4 4 i n . 0.246 in. 0 .245 in.

E - 1 1

E-3 Pitot Tube C a l i b r a t i o n

E-12

PITOT TUBE CALIBPATTON FOlW

C a l i h r a t e d by: KCs

Date: 1 - 6 - 7 9 C p s t d = 0*7? 0.55 O K a s r e q u i r e d + "std E

FLo w FL z

c = P i t o t t u b e c o e f f i c i e n t o f standard t y p e p i t o t t u b e Ps t d

Dev. = C - c (must be r: 0.01)

C ( d i f f e r e n c e )

P ( S ) p c.: , d n 3 (must h e 5 0.01)

P

E-13

. .

APPENDIX F

SCOPE OF WORK

F-1 Copy of U.S. EPA Work Assignment and Sampling and Analysis Schedule

F- 1

F-1 Copy of U.S. EPA Work Assignment and Sampling and Analysis Schedule

F-2

...... ........... .............. 1 ~ ~ ; , . ~ ~ - . . - - ....

1 13 AUG ij:ju l l L E

Source T e s t , o f 6 r i ck Kiln

s e t f o r t h i n the a t t a c h e d "Source Sampling and Aiial.ysis S c t t d u i e " z t Il;c fo.Ilo:.iirig s i t e :

Coiiipariy Ilaiiie: Chatham Brick diid T i l e Lo c J. t i 011 : Gul f , North Caro l ina I n d u s t r y : Bui lding fjrick and S t r u c t u r a l Clay P r o j e c t !lo.: 80-BKK-5

,

s h a l l p rovide 15 cop ie s o f the f i n a l r e p o r t with appendices mtl 1s c o p i e s it: :?I

summary w i t h o u m e n d i c e s .

Data Forins s h a l l be submi t ted d i r e c t l y t o J . E . ikCai-l.ey, Eni iss - io r i i<easu&nent ljrwcti, ESCD, I.lai1 Drop 13, Research T r i a n g l e Park , North Carol.iria ?77l ' l .

U p o n . n o t i f i c a t i o n o f approval of the proEosed source t e s t r e p o r t , tilo Con t rac to r

A l l pretest survsy , proposed f i n a l , a n d find source t e s t reixrr-tr, w t l SOl'OAT

. .

All samples s h a l l be shipped to: r I / A

..

f

F-4

a,

..

.. .I 2 .

Y n 1 c

! i F-5

-L-

..