AQ_F_1900009_20160711_ST_RvwMemo (4)

Chatham County
DIVISION OF AIR QUALITY
Technical Services Section
July 11, 2016
MEMORANDUM
To: Patrick Butler, P.E., Raleigh Regional Office
From: Gregg O'Neal, Stationary Source Compliance Branch (SSCB) M,
Subject: General Shale Brick, Inc., Brickhaven Plant#25,
Facility No. 05-19-00009, Tracking No. 2015-165ST
Moncure, Chatham County, North Carolina, Air Permit No. 04384T38
Particulate, Hydrogen Chloride (HCI) and Hydrogen Fluoride (HF) Emissions Testing
Brick Tunnel Kiln (ID No. KS-K4K)
Performed on September 24, 2015 by Environmental Source Samplers, Inc., (ESS)
A report of the subject testing has been reviewed. The Particulate (PM), Hydrogen Chloride
(HCI) and Hydrogen Fluoride (HF) results have been found acceptable.
The tested emission source is KS-K4K. The primary operation scenario (POS)for KS-K4K is
natural gas/propane-fired brick tunnel kiln (25.9 million Btu per hour heat input and 20.55 tons per
hour maximum fired brick production rate). Brick tunnel kiln KS-K4K emissions are controlled by
a dry limestone adsorber(DLA) ID No. CD-K4DLA. Testing was performed in the POS with
CD-K4DLA in operation.
15A NCAC 2D .1109: Case-by-Case MACT applies. Permit Condition 2.1-A.4.b stipulates the
Case-by-Case MACT limits for Filterable PM and HCI-equivalent HF. The pollutants, methods,
emissions results, and limits are tabulated below:
Brick Tunnel Kiln KS-K4K: September 24, 2015 Test
Fired Brick EPA Emissions
Production Pollutant Method Test Results Limit Standard Compliance
1.62lb/hr --- --- ---
Filterable PM 5 0.10 lb/ton 0.17 Ib/ton 15A NCAC 2D .1109 Indicated
Permit Section 2.2.A.b
15.6 ton/hr HCI-equivalent 0.71 Ib/hr 18.28 Ib/hr* 15A NCAC 2D .1109 Indicated*
Or Permit Section 2.2.A.b
(76% of 2.32 ppmvd
Maximum) HCI 26A 0.41lb/hr
0.03 lb/ton
0.88 ppmvd -� --- ---
HF 0.09 Ib/hr
0.01 lb/ton
* The 15A NCAC 2D .1109 HCI-equivalent permit limit is for the emissions from kilns (ES-K1, ES-K2, ES-
K3K, and ES-K4K) not kiln 1 alone, assuming only ES-K4K in operation compliance was indicated.
During testing the limestone feed rate was set at 30 Ib/hr feeding (Stone Chem Grade 3/8
inch/Bulk)to CD-K4DLA.
Compliance was indicated with 15A NCAC 2D .1109 for Filterable PM and HCI-equivalent
emissions from kiln KS-K4K as controlled by CD-K4DLA. If there are any questions concerning
this matter, please contact me at [phone] or gregg.oneal(c-ncdenr.gov.
cc: Central Files, Chatham County
IBEAM Documents - 1900009