AQ_F_0400043_20161214_ST_STO-Rpt

NORTH CAROLINA DIVISION OF Fayetteville Regional Office
AIR QUALITY Triangle Brick Cc -Wadesboro
NC Facility ID 0400043
Stack Test Observation Report County/FIPS: Anson/007
Date: 12/14/2016
Facility Data Compliance Data
Triangle Brick Cc -Wadesboro Observation Date 09/13/2016
US Hwy 52 Observer's Name Heather Carter
Wadesboro,NC 28170 Operating Status Operating
Lat: 35d 1.1463m Long: 80d 5.1235m Action Code 23/STACK TEST
SIC: 3251 /Brick And Structural Clay Tile OBSERVED
NAILS: 327121/Brick and Structural Clay Tile Manufacturing
Contact Data Permit Data
Facility Contact Authorized Contact Technical Contact Permit 08179/T09
Nathan Wallace Howard Brown,Jr. Howard Brown,Jr. Issued 11/14/2016
Plant Manager VP of Production and VP of Production and Expires 8/31/2018
_ [phone] Engineering Engineering Classification Title V
[phone] [phone] Permit Status Active
Inspector's Signature: Comments:
Source Test Tracking#2016-213ST
Date ofSignature: /d /cf /(.
I. DIRECTIONS TO SITE:
Triangle Brick is located on US 52 in Wadesboro, NC, Anson County. From FRO, take US 401 south to
US 74; turn right onto US 74 West. Follow US 74 thru Wadesboro. On the west side of Wadesboro, turn
right, following US 52 north. Go approximately 3.5 miles and turn right into the first facility entrance;
the office is on the left.
11. SAFETY:
_ Safety glasses and shoes required; hard hat and ear protection optional. An operating kiln is hot to touch;
exiting bricks and cars are hot. Keep hands out of brick-making mechanisms, grinders and extruders.
111.FACILITY DESCRIPTION:
Triangle Brick Co. - Wadesboro is the second largest brick plant in the country. They make a variety of
bricks from clay and shale mined onsite. The material they mine is a consistent mixture of clay and shale.
As the material is mined, it is trucked up the hill to the facility where it is fed through a sizing grate. The
smaller material passes via conveyors to the storage shelter and the oversized material goes through a jaw
crusher to reduce the size and then continues on to the storage shelter. There are two plants on site and
the material from the storage shed feeds both. From the storage shelter material is scooped into a feeder,
run through a scalper (oversized material goes to hammer mill) then material (the consistency of
cornmeal) is conveyed to storage silos. From the storage silos the material is sent through two pug mills
in series where it is combined with water and mixed to an even consistency then fed through a machine
that extrudes the brick in a slab. The slabs are treated with a decorative coating (carrying agent is a
sawdust/loam mixture), cut into individual bricks and then loaded on a `car' for transport through the
dryer and kilns. Hydrogen Fluoride from the kilns is controlled by a dry lime adsorber (DLA) installed
on each kiln. The firing takes more than two days. After firing the bricks are packaged into skid loads
(by a very cool robot)and stored prior to purchase and shipment.

IV.PURPOSE OF SOURCE TESTING
The source testing being performed on 13 September 2016 is being conducted to show compliance with
the 15A NCAC 2D .1109"112j Case-by-Case-MACT(Brick). The testing will determine HF,HCL and
Filterable PM emissions from Kiln#2(K-2) operating with a Dry Lime Adsorber,utilizing EPA Methods
5 and 26A. The facility must demonstrate compliance with the following limits: filterable PM limit of
0.17 lb/ton of oven fired brick; HCL-equivalent(HCL,)emission rate of 9.455 lbs/hr total from both
kilns. The source test is required within 180 days after the compliance date of 4 September 2016.
The testing is being completed on NG-fired K-2,operating with DLA, at a rate of approx. 25 tph(18 cars
x 18,144 brick/car x 3.7 lb/brick/24/2000=ton/hr). The DLA bypass damper was locked into the
closed position,forcing exhaust through the DLA. The two test methods were being performed
simultaneously. The test company had the audit samples on site,and I took pies of each container.
The facility recently requested a minor modification of their Title V Air Permit to include the operation of
the DLAs on the Kilns. They requested this modification so that they could operate the DLAs and test
after control to demonstrate compliance with the Case-by-Case Brick MACT. The proposed modification
included testing,monitoring, and recordkeeping requirements associated with the operation of the DLAs.
The protocol was submitted by the company and received at the FRO on 1 August 2016. The RCO SSCB
reviewed the protocol and issued an approval letter on 23 August 2016.
V. SOURCE TEST OBSERVATIONS
On 13 September 2016,I,Heather Carter, and Dan Thoma,both from the FRO DAQ, arrived at the
facility to observe the source test and conduct their annual compliance inspection. We initially met with
Nathan Wallace,Plant Manager, in the front office. Later we were joined by Ricky Merritt,TBC Env
Contact, and Beth Barfield,ERM consultant for TBC. We discussed the purpose of the testing,process
rate during the test, and any issues that had come up or any concerns they had. We went to where the
testers were set up and met with Michael Cantom,Anthony King, and Dustin Warrington,all from ERM.
The ERM testing branch is conducting this source test. Dustin Warrington is the test POC, 865-806-2029
Mr.Thoma and I noticed some VE from the DLA on Kiln#2 so he positioned himself to observe the
stack at proper sun angle and distance for at least 30 minutes. He returned and noted that the VE had
dissipated-after a few minutes and that subsequent readings were all zero (0).
Dustin showed me the audit samples,which I documented with photographs. The process rate during the
entire test is supposed to be an 18 car push, —25 tons/hr fired brick. They were using a.305 nozzel
diameter to give them a 60 min sample time. They were sampling at 24 points(12 pts for each port)at
2.5 min/point. Test Run#1 started at 1:21pm and concluded at 2:27pm. Drift for Run#1 was 0.4%. The
testers indicated they were seeing a spike in CO2/02 data logger before the 20 min push cycle but that it
would balance back out just after. Test Run#2 stared at 3:14pm, and we left the site at 4pm,before the
run was completed. Aside from the initial VE noted before Test Run#1 started,we observed zero (0)VE
during the testing.
The limestone feeder setting at the DLA is set to 2 mins screw on and 2 min screw off. of the 2 min the
screw is on the peeler is run at 30 sec on and 30 sec off.The source of limestone is Lhoist North America,
Crab Orchard TN. The limestone is listed as"Chemical"grade 3/8 inch. The bypass damper was locked
closed(forcing air through the DLA). Mr.Wallace stated that the limestone hopper has a low level
indicator and audible and visual alarms engage if the limestone level falls below the indicator.
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VI. COMPLIANCE STATEMENT
From observations made during the test, it appears that the testers were following the protocol as
submitted for the testing of Kiln#2 after the DLA.
/hsc
Attachments: Pictures of Audit Samples

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OERA Order Confirmation
{ A Waters Company Page 1 of 1
_ • r- 1-61M046
Name: Anthony King Environmental Resources Manage TestAmerica-Knoxville Account E041240
Email: [e-mail] 4140 Parklake Avenue 5815 Middlebrook Pike Date 07-17-2016
Phone:[phone] Ste 110 Knoxville,TN 37921
Fax: Raleigh,NC 27612 PD#/CC Type Triangle Brick
Attn: Accts/Rachel Kazanski Alm: Wlllam Anderson Processed Wadesbor
Darren Sauer
CS Representative Claire Toon
Shipping FedEx Econ
Payment Terms NET 30
1 9/6/2016 1440 Hydrogen Halides&Halogens In Impinger Bolo PT $151.00 I $151.00
comments; Start 09/I121 End:09116118
Ss Y TPID:Triangle Prick 2016Comp Ilan ce,Wadea amKIn2
r.E Teslenvironmental Resources Management
Facility;Triangle Bdck Company
H drogen Chloride 23.73 mg/L Laboratory:TestAmerica Knoxville
Hydrogen Fluoride @ 81.58 mg/L Agency:NC DAD Fayetteville
$151.00
Trade Discount $0.00
Handling $10.00
Freight $49.73
COD Surcharge $0.00
Tax $0.co
$210.73
0 1FFERENEEh The only PT provider with
MEASURABLE' results available in 2 days
16341 Table Mountain Parkway,Golden C0 60403 I Telephone:[phone] I Toll Free:800-372-0122 1 Fax:[phone] I eragc.com

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' UNIFORM STRAIGHT BILL OF LADY
Amenca ORIGINAL-NOT NEGOTIABLE
Lhoist Group 11311.1.of LADING No. 910023171
DATE 9/7/2016 3:40:31 Ph
RECEIVED,subject to the classifications and tariffs in effect on the date of the issue of this Bill of Lading.
SHIPPER Crab Orchard Truck
FROM FOB Crab Orchard Plant 10583 Hwy 70 E Crab Orchard, TN 37723
"Customerhareby acknowhidgas its responsiblilty to remove lira product tendered on the dallvery vehicle.Due to tha nature of the product end the
delivery mode and sltus,a que w of the product may remain in the delivery vehicle totiowing dlatdbution.Customer may remove such quantity,but
if not removed,it agrees,by the signaturo below fe pay for the entire quantity Indicated hereon which is tendered and thus avallabla for removal."
eONSIGNED TO 213031 TRIANGLE BRICK COMPANY
DESTINATION TRIANGLE BRICK WADESBORO CPL WADESBORO NO
WADESBORO NO 28170
69839 HAMPTON TRUCKING LLC TRUCIc tD 866
TRAILER ID
DESCRIPTION OF ARTICLES,SPECIAL MARKS,AND EXCEPTION$ 'WEIGHT Subject to Section 7 of conditions, i I$vt cot to eonac0on this shipment is to be delivered to the
5258 Stone Chem Grade 3l81nch 24.96 Ton consignee without recourse on the
consignor,the consignor shall sign th
following statement:
The Carrier shall not make delivery
this shipment without payment of freit
and all other lawful changes.
(Signature of consignor)
If the charges are to be prepaid,wrl
stamp here,"To be Prepaid."
9/7/2016 3:40:31 PM Gross weight: 79,280 LB Freight Collect
9/7/2016 2:14:21 PM Tare weight: 29,360 LB Salee af-#: 003 S 2
Net weight: 49,920 LB 10
TRAILER a536 etoauht Release#:
FREIGHT:COLLECT 24.96 Ton 0,00 0,00 BIN: 92
LOADED BY:ad Freight 0.00 0.00 P.O: NW051116
Other 0,00
Tax: 10 6.0000 ^q qg Dispatch#: 140207273
To41r 0.00
$HIPPER Michael Austin
RECEIVED BY CONSIGNEE 0741 9HZ TN,
PERMANENT ADDRESS OF SHIPPER 10683 Hwy 70 1 Crab Orchard,TN 37720

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J NORTH CAROLINA DIVISION OF AIR QUALITY Fayetteville Regional Office
Triangle Brick Cc -Wadesboro
Stack Test Observation Report
NC Facility ID 0400043
Stack Test Date: 09/13/2016 Coun /FIPS: Anson/007
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