Emission Factor Documentation for AP-42
Section 11.3
BRICK AND STRUCTURAL CLAY PRODUCT
MANUFACTURING
Final Report
For U. S. Environmental Protection Agency
Office of Air Quality Planning and Standards
Emission Factor and Inventory Group
EPA Contract 68-D2-0159
Work Assignment No. 4-02
MRI Project No. 4604-02
August 1997
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Emission Factor Documentation for AP-42
Section 11.3
BRICK AND STRUCTURAL CLAY PRODUCT
MANUFACTURING
Final Report
For U. S. Environmental Protection Agency
Office of Air Quality Planning and Standards
Emission Factor and Inventory Group
Research Triangle Park, NC 27711
Attn: Mr. Ron Myers (MD-14)
Emission Factor and Inventory Group
EPA Contract 68-D2-0159
Work Assignment No. 4-02
MRI Project No. 4604-02
August 1997
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NOTICE
The information in this document has been funded wholly or in part by the United States
Environmental Protection Agency under Contract No. 68-D2-0159 to Midwest Research Institute. It has
been reviewed by the Office of Air Quality Planning and Standards, U. S. Environmental Protection Agency,
and has been approved for publication. Mention of trade names or commercial products does not constitute
endorsement or recommendation for use.
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PREFACE
This report was prepared by Midwest Research Institute (MRI) for the Office of Air Quality
Planning and Standards (OAQPS), U. S. Environmental Protection Agency (EPA), under Contract
No. 68-D2-0159, Work Assignment Nos. 3-01 and 4-02. Mr. Ron Myers was the requester of the work.
Approved for:
MIDWEST RESEARCH INSTITUTE
Roy Neulicht
Program Manager
Environmental Engineering Department
JeffShular
Director, Environmental Engineering
Department
August 1997
in
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IV
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TABLE OF CONTENTS
Page
1. INTRODUCTION 1-1
2. INDUSTRY DESCRIPTION 2-1
2.1 INDUSTRY CHARACTERIZATION 2-1
2.2 PROCESS DESCRIPTION 2-1
2.3 EMISSIONS 2-3
2.4 EMISSION CONTROL TECHNOLOGY 2-4
3. GENERAL DATA REVIEW AND ANALYSIS PROCEDURES 3-1
3.1 LITERATURE SEARCH AND SCREENING 3-1
3.2 DATA QUALITY RATING SYSTEM 3-2
3.3 EMISSION FACTOR QUALITY RATING SYSTEM 3-3
4. REVIEW OF SPECIFIC DATA SETS 4-1
4.1 INTRODUCTION 4-1
4.2 REVIEW OF SPECIFIC DATA SETS 4-1
4.2.1 Reference 1 4-1
4.2.2 Reference 2 4-2
4.2.3 Reference 3 4-3
4.2.4 Reference 4 4-3
4.2.5 Reference 5 4-5
4.2.6 Reference 6 4-5
4.2.7 Reference 7 4-5
4.2.8 Reference 8 4-6
4.2.9 Reference 9 4-6
4.2.10 Reference 10 4-6
4.2.11 Reference 12 4-7
4.2.12 Reference 13 4-7
4.2.13 Reference 14 4-7
4.2.14 Reference 15 4-8
4.2.15 Reference 17 4-8
4.2.16 Reference 18 4-9
4.2.17 Reference 19 4-9
4.2.18 Reference 20 4-9
4.2.19 Reference 21 4-9
4.2.20 Reference 22 4-10
4.2.21 Reference 23 4-10
4.2.22 Reference 24 4-11
4.2.23 Reference 25 4-12
4.2.24 Reference 29 4-12
4.2.25 Reference 30 4-13
4.2.26 Reference 31 4-13
4.2.27 Reference 32 4-14
4.2.28 Reference 33 4-14
4.2.29 Reference 34 4-14
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TABLE OF CONTENTS (continued)
Page
4.2.30 Reference 35 4-15
4.2.31 Reference 36 4-15
4.2.32 Reference 37 4-15
4.2.33 Reference 38 4-15
4.2.34 Reference 39 4-16
4.2.35 Review of FIRE and SPECIATE Data Base Emission Factors 4-16
4.3 DEVELOPMENT OF CANDIDATE EMISSION FACTORS 4-16
4.3.1 Filterable PM 4-56
4.3.2 Filterable PM-10 4-57
4.3.3 Condensible PM 4-58
4.3.4 Total Organic Compounds 4-59
4.3.5 Volatile Organic Compounds 4-59
4.3.6 Methane and Ethane 4-60
4.3.7 Carbon Monoxide 4-60
4.3.8 Carbon Dioxide 4-61
4.3.9 Nitrogen Oxides 4-61
4.3.10 Sulfur Dioxide 4-62
4.3.11 Sulfur Trioxide 4-62
4.3.12 Hydrogen Fluoride 4-63
4.3.13 Total Fluorides 4-63
4.3.14 Hydrochloric Acid 4-64
4.3.15 Metals 4-64
4.3.16 Volatile and Semivolatile Organic Compounds 4-65
4.4 SUMMARY OF CHANGES TO AP-42 SECTION 4-65
4.4.1 Section Narrative 4-65
4.4.2 Emission Factors 4-65
5. PROPOSED AP-42 SECTION 5-1
VI
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LIST OF FIGURES
Figure Page
2-1 Typical brick manufacturing process 2-2
2-2 Sulfur content of soils 2-5
2-3 Fluorine content of soils 2-7
LIST OF TABLES
Table Page
4-1 SUMMARY OF TEST DATA FOR BRICK AND STRUCTURAL CLAY
PRODUCT MANUFACTURING 4-17
4-2 EMISSION FACTOR DEVELOPMENT FOR BRICK AND STRUCTURAL
CLAY PRODUCT MANUFACTURING 4-33
4-3 SUMMARY OF EMISSION FACTORS FOR BRICK AND STRUCTURAL
CLAY PRODUCT MANUFACTURING 4-47
4-4 SUMMARY OF PARTICLE SIZE DISTRIBUTION DATA FOR FILTERABLE
PM EMISSIONS FROM KILNS 4-55
4-5 AVERAGE PARTICLE SIZE DISTRIBUTION FOR FILTERABLE PM
EMISSIONS FROM KILNS 4-55
vn
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EMISSION FACTOR DOCUMENTATION FOR AP-42 SECTION 11.3
BRICK AND STRUCTURAL CLAY PRODUCT MANUFACTURING
1. INTRODUCTION
The document Compilation of Air Pollutant Emission Factors (AP-42) has been published by the
U. S. Environmental Protection Agency (EPA) since 1972. Supplements to AP-42 have been routinely
published to add new emission source categories and to update existing emission factors. AP-42 is routinely
updated by EPA to respond to new emission factor needs of EPA, State and local air pollution control
programs, and industry.
An emission factor is a representative value that attempts to relate the quantity of a pollutant released
to the atmosphere with an activity associated with the release of that pollutant. Emission factors usually are
expressed as the weight of pollutant divided by the unit weight, volume, distance, or duration of the activity
that emits the pollutant. The emission factors presented in AP-42 may be appropriate to use in a number of
situations, such as making source-specific emission estimates for areawide inventories for dispersion
modeling, developing control strategies, screening sources for compliance purposes, establishing operating
permit fees, and making permit applicability determinations. The purpose of this report is to provide
background information from test reports and other information to support revisions to AP-42 Section 11.3,
Bricks and Related Clay Products.
This background report consists of five sections. Section 1 includes the introduction to the report.
Section 2 gives a description of the brick and structural clay product manufacturing industry. It includes a
characterization of the industry, a description of the different process operations, a characterization of
emission sources and pollutants emitted, and a description of the technology used to control emissions
resulting from these sources. Section 3 is a review of emission data collection (and emission measurement)
procedures. It describes the literature search, the screening of emission data reports, and the quality rating
system for both emission data and emission factors. Section 4 details how the revised AP-42 section was
developed. It includes the review of specific data sets, a description of how candidate emission factors were
developed, and a summary of changes to the AP-42 section. Section 5 presents the AP-42 Section 11.3,
Brick and Structural Clay Product Manufacturing. The name of the section was changed to more accurately
define the source category.
1-1
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2. INDUSTRY DESCRIPTION
2.1 INDUSTRY CHARACTERIZATION1'2
The brick and structural clay products industry is made up primarily of facilities that manufacture
structural brick from clay, shale, or a combination of the two. These facilities are classified under standard
industrial classification (SIC) code 3251, brick and structural clay tile. Facilities that manufacture structural
clay products, such as clay pipe, adobe brick, chimney pipe, flue liners, drain tiles, roofing tiles, and sewer
tiles, are classified under SIC code 3259, structural clay products, not elsewhere classified.
In 1992, approximately 220 facilities manufactured brick and structural clay tile, with a total value of
shipments of about $1.1 billion. Approximately 65 facilities produced other structural clay products, with a
total value of shipments of about $126 million. North Carolina, Ohio, South Carolina, and Texas were the
leading brick and structural clay tile producing States, while California and Ohio were the leading producers
of other structural clay products. In 1990, approximately 77 percent of all brick manufacturing plants used
natural gas (120 of the 152 plants that responded to a survey used natural gas) as the primary fuel for firing
kilns, with the remainder of the plants using sawdust (15 plants) and coal (16 plants). One plant used fuel
oil, and 31 plants had fuel oil available as a backup fuel. The trend in the industry is towards natural gas-
fired kilns.
2.2 PROCESS DESCRIPTION3'6
The manufacture of brick and structural clay products involves mining, grinding, screening and
blending of the raw materials followed by forming, cutting or shaping, drying, firing, cooling, storage, and
shipping of the final product. A typical brick manufacturing process is shown in Figure 2-1.
The raw materials used in the manufacture of brick and structural clay products include surface clays
and shales, which are mined in open pits. The moisture content of the raw material varies among plants, from
a low of about 3 percent to a high of about 15 percent. Some facilities have on-site mining operations, while
others bring in raw material by truck or rail. The raw material is typically loaded by truck or front-end loader
into a primary crusher for initial size reduction. The material is then conveyed to a grinding room, which
houses several grinding mills and banks of screens that produce a fine material that is suitable for forming
bricks or other products. Types of grinding mills typically used include dry pan grinders, roller mills, and
hammermills. From the grinding room, the material is conveyed to storage silos or piles, which typically are
enclosed. The material is then either conveyed to the mill room for brick forming or conveyed to a storage
area.
Most brick are formed by the stiff mud extrusion process, although brick are also formed using the
soft mud and dry press processes (there may be no plants in the U.S. currently using the dry press process).
A typical stiff mud extrusion line begins with a pug mill, which mixes the ground material with water and
discharges the mixture into a vacuum chamber. Some facilities mix additives such as barium carbonate,
which prevents sulfates from rising to the surface of the brick, with the raw material prior to extrusion. The
moisture content of the material entering the vacuum chamber is typically between 14 and 18 percent. The
vacuum chamber removes air from the material, which is then continuously augured or extruded through dies.
The resulting continuous "column" is lubricated with oil or other lubricant to reduce friction during extrusion.
If specified, various surface treatments, such as manganese dioxide, iron oxide, and iron chromite can be
applied at this point. These treatments are used to add color or texture to the product. A wire-cutting
machine is used to cut the column into individual bricks, and then the bricks are mechanically
2-1
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o
o
o
o
MIMING
OPERATIONS
RAW MATERIAL
STORAGE PILES
(3-D5-DD3-03)
PRIMARY
(3-05-003-40)
GRINDING AND
SCREENING
OPERATIONS
(3-05-B03-B2)
GROUND MATERIAL
(3-05-003-03)
FORMING, CUTTING.
AND STACKING
OPERATIONS
EXHAUST STREAM
O
PM EMISSIONS
2 ) ORGANIC POLLUTANT EMISSIONS
^-S
—v
3 J GASEOUS EMISSIONS FROM FUEL COMBUSTION
HYDROGEN FLUORIDE EMISSIONS
0
O000
O©4©0
TO NATURAL GAS-, COAL-,
OR SAWDUST-FIRED KILN
WASTE HEAT FROM THE
KILN COOLING ZONE
SAWDUST STORAGE
Figure 2-1. Typical brick manufacturing process.
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or hand set onto kiln cars. All structural tile and most brick are formed by this process. Prior to stacking,
some facilities mechanically process the unfired bricks to create rounded imperfect edges that give the
appearance of older worn brick.
The soft mud process is usually used with clay that is too wet for stiff mud extrusion. In a pug mill,
the clay is mixed with water to a moisture content of 20 to 30 percent, and the bricks are formed in molds and
are dried before being mechanically stacked onto kiln cars. In the dry press process, clay is mixed with a
small amount of water and formed in steel molds by applying pressure of 3.43 to 10.28 megapascals (500 to
1,500 pounds per square inch).
Following forming and stacking, the brick-laden kiln cars enter a predryer or a holding area and are
then loaded into the dryer. Dryers typically are heated to about 204 °C (400 °F) using waste heat from the
cooling zone of the kiln. However, some plants heat dryers with gas or other fuels. Dryers may be in-line or
totally separate from the kiln. From the dryer, the bricks enter the kiln. The most common type of kiln used
for firing brick is the tunnel kiln, although some facilities operate downdraft periodic kilns or other types of
kilns. A typical tunnel kiln ranges from about 104 meters (m) (340 feet [ft]) to 152 m (500 ft) in length and
includes a dryer, a firing zone, and a cooling zone. The firing zone typically is maintained at a maximum
temperature of about 1090°C (2000 °F). During firing, small amounts of excess fuel are sometimes
introduced to the kiln atmosphere, creating a reducing atmosphere that adds color to the surface of the bricks.
This process is called flashing. After firing, the bricks enter the cooling zone, where they are cooled to near
ambient temperatures before leaving the tunnel kiln. The bricks are then stored and shipped.
A periodic kiln is a permanent brick structure with a number of fireholes through which fuel enters
the furnace. Hot gases from the fuel are first drawn up over the bricks, then down through them by
underground flues, and then out of the kiln to the stack.
In all kilns, firing takes place in six steps: evaporation of free water, dehydration, oxidation,
vitrification, flashing, and cooling. Natural gas is the fuel most commonly used for firing, followed by coal
and sawdust. Some plants have fuel oil available as a backup fuel. Most natural gas-fired plants that have a
backup fuel use vaporized propane as the backup fuel. For most types of brick, the entire drying, firing, and
cooling process takes between 20 and 50 hours.
Flashing is used to impart color to bricks by adding uncombusted fuel (other materials such as zinc,
used tires, or used motor oil are also reportedly used) to the kiln to create a reducing atmosphere. Typically,
flashing takes place in a "flashing zone" that follows the firing zone, and the bricks are rapidly cooled
following flashing. In tunnel kilns, the uncombusted fuel or other material typically is drawn into the firing
zone of the kiln and is burned.
2.3 EMISSIONS3'7'12
Emissions from brick manufacturing facilities include particulate matter (PM), PM less than or equal
to 10 microns in aerodynamic diameter (PM-10), PM less than or equal to 2.5 microns in aerodynamic
diameter (PM-2.5), sulfur dioxide (SO2), sulfur trioxide (SO3), nitrogen oxides (NOX), carbon monoxide
(CO), carbon dioxide (CO2), metals, total organic compounds (TOC) (including methane, ethane, volatile
organic compounds [VOC], and some hazardous air pollutants [HAP]), and fluorides. Factors that may
affect emissions include raw material composition and moisture content, kiln fuel type, kiln operating
parameters, and plant design. Emissions from the manufacture of other structural clay products are expected
to be similar to emissions from brick manufacturing.
2-3
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The primary sources of PM, PM-10, and PM-2.5 emissions are the raw material grinding and
screening operations and the kilns. Other sources of PM emissions include sawdust dryers used by plants
with sawdust-fired kilns, coal crushing systems used by plants with coal-fired kilns, and fugitive dust sources
such as paved roads, unpaved roads, and storage piles.
Combustion products, including SO2, NOX, CO, and CO2, are emitted from fuel combustion in brick
kilns and some brick dryers. Brick dryers that are heated with waste heat from the kiln cooling zone are not
usually a source of combustion products because kilns are designed to prevent combustion gases from
entering the cooling zone. Some brick dryers have supplemental gas burners that produce small amounts of
NOX, CO, and CO2 emissions. These emissions are sensitive to the condition of the burners. The primary
source of SO2 emissions from most brick kilns is the raw material, which may contain sulfur compounds.
Some facilities use raw material with a high sulfur content, and have higher SO2 emissions than facilities that
use low-sulfur raw material. In addition, some facilities use additives that contain sulfates, and these
additives may contribute to SO2 emissions. Figure 2-2 shows the sulfur content (in ppm) of soil samples
taken from locations throughout the United States. The samples, which were taken at a depth of about 20 cm,
are not specific to clays and shales used for brick manufacturing, but they provide insight into regional
variations in the sulfur content of soils. The sulfur content of the soil samples ranges from less than 0.08
percent to 4.8 percent and averages 0.16 percent.
Organic compounds, including methane, ethane, VOC, and some HAP, are emitted from both brick
dryers and kilns. These compounds also are emitted from sawdust dryers used by facilities that fire sawdust
as the primary kiln fuel. Organic compound emissions from brick dryers may include contributions from the
following: (1) petroleum-based or other products in those plants that use petroleum-based or other lubricants
in extrusion, (2) light hydrocarbons within the raw material that vaporize at the temperatures encountered in
the dryer, and (3) incomplete fuel combustion in dryers that use supplemental burners in addition to waste
heat from the kiln cooling zone. Organic compound emissions from kilns are the result of volatilization of
organic matter contained in the raw material and kiln fuel.
Hydrogen fluoride (HF) and other fluoride compounds are emitted from kilns as a result of the
release of the fluorine compounds contained in the raw material. Fluorine typically is present in brick raw
materials in the range of 0.01 to 0.06 percent. As the green bricks reach temperatures of 500° to 600°C
(930° to 1110°F), the fluorine in the raw material forms HF and other fluorine compounds. Much of the
fluorine is released as HF. Because fluorine content in clays and shales is highly variable, emissions of HF
and other fluoride compounds vary considerably depending on the raw material used. Figure 2-3 shows the
fluorine content (in ppm) of soil samples taken from locations throughout the United States. The samples,
which were taken at a depth of about 20 cm, are not specific to clays and shales used for brick manufacturing,
but they provide insight into regional variations in the fluorine content of soils. The fluorine content of the
soil samples ranges from less than 0.001 percent to 0.37 percent and averages 0.043 percent.
2.4 EMISSION CONTROL TECHNOLOGY3'6
A variety of control systems may be used to reduce PM emissions from brick manufacturing
operations. Grinding and screening operations are sometimes controlled by fabric filtration systems, although
many facilities process raw material with a relatively high moisture content (greater than 10 percent) and do
not use add-on control systems. Most tunnel kilns are not equipped with control devices, although fabric
filters or wet scrubbers are sometimes used for PM removal. Particulate matter
2-4
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2-5
-------
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2-6
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2-7
102° 100C
-------
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emissions from fugitive sources such as paved roads, unpaved roads, and storage piles can be controlled
using wet suppression techniques.
Gaseous emissions from brick dryers and kilns typically are not controlled using add-on control
devices. However, dry scrubbers that use limestone as a sorption medium are sometimes used to control HF
emissions; control efficiencies of 95 percent or higher have been reported at one plant operating this type of
scrubber. Also, wet scrubbers are used at one facility. These scrubbers, which use a soda ash and water
solution as the scrubbing liquid, provide effective control of HF and SO2 emissions. Test data show that the
only high-efficiency packed tower wet scrubber operating in the U.S. (at brick plants) achieves control
efficiencies greater than 99 percent for SO2 and total fluorides. A unique "medium-efficiency" wet scrubber
operating at the same plant has demonstrated an 82 percent SO2 control efficiency.
Process controls are also an effective means of controlling kiln emissions. For example, facilities
with coal-fired kilns typically use a low-sulfur, low-ash coal to minimize SO2 and PM emissions. In addition,
research is being performed on the use of additives (such as lime) to reduce HF and SO2 emissions.
REFERENCES FOR SECTION 2
1. 1992 Census of Manufactures, Cement and Structural Clay Products, U. S. Department of Commerce,
Washington, D.C., 1995.
2. Telephone communication between B. Shrager, Midwest Research Institute, Gary, NC, and N. Cooney,
Brick Institute of America, Reston, VA, October, 20, 1994.
3. A Compilation of Air Pollutant Emission Factors, U. S. Environmental Protection Agency, Research
Triangle Park, NC, October 1986.
4. Written communication from J. Dowdle, Pine Hall Brick Co., Inc., Madison, NC, to R. Myers, U. S.
Environmental Protection Agency, Research Triangle Park, NC, September 1992.
5. Written communication from B. Shrager, Midwest Research Institute, Gary, NC, to R. Myers, U. S.
Environmental Protection Agency, Research Triangle Park, NC, April 1993.
6. Written communication from B. Shrager, Midwest Research Institute, Gary, NC, to R. Myers, U. S.
Environmental Protection Agency, Research Triangle Park, NC, September 1993.
7. D. A. Brosnan, "Monitoring For Hydrogen Fluoride Emissions", Ceramic Industry, July 1994.
8. Emission Testing at a Structural Brick Manufacturing Plant—Final Emission Test Report for Testing
at BeIden Brick Company, Plant 6, Sugarcreek, Ohio, U. S. Environmental Protection Agency,
Research Triangle Park, NC, February 1995.
9. Final Test Report for U. S. EPA Test Program Conducted At General Shale Brick Plant, Johnson
City, TN, U. S. Environmental Protection Agency, Research Triangle Park, NC, December 1993.
10. Flue Gas Characterization Studies Conducted on the 30B Kiln and Dryer Stacks in Atlanta Georgia
for General Shale Corporation, Guardian Systems, Inc., Leeds, AL, March 1993.
2-9
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11. Final Test Report for U. S. EPA Test Program Conducted At Pine Hall Brick Plant, Madison, NC,
U. S. Environmental Protection Agency, Research Triangle Park, NC, August 1993.
12. D. Brosnan, "Technology and Regulatory Consequences of Fluorine Emissions in Ceramic
Manufacturing", American Ceramic Industry Bulletin, 71 (12), pp 1798-1802, The American Ceramic
Society, Westerville, OH, December 1992.
13. Written Communication from N. Cooney, Brick Institute of America, Reston, VA, to R Myers, U. S.
Environmental Protection Agency, Research Triangle Park, NC, July 24, 1995.
14. Written Communication from J. Saitas, Texas Natural Resource Conservation Commission, Austin, TX,
to R. Myers, U. S. Environmental Protection Agency, Research Triangle Park, NC, June 29, 1995.
15. Written communication from J. Southerland, North Carolina Department of Environment, Health,
and Natural Resources, Raleigh, NC, to Ron Myers, U. S. Environmental Protection Agency,
Research Triangle Park, NC, January 31, 1997.
16. Written communication from P. Kimes, Utah Department of Environment Quality, Division of Air
Quality, Salt Lake City, UT, to Ron Myers, U. S. Environmental Protection Agency, Research
Triangle Park, NC, January 30, 1997.
17. Written communication from J. Taylor, Georgia Department of Natural Resources, Environmental
Protection Division, Atlanta, GA, to Ron Myers, U. S. Environmental Protection Agency, Research
Triangle Park, NC, January 27, 1997.
18. Written communication from N. Cooney, Brick Institute of America, Reston, VA, to Ron Myers, U.
S. Environmental Protection Agency, Research Triangle Park, NC, January 30, 1997.
19. Written communication from D. Brosnan, Center for Engineering Ceramic Manufacturing, Clemson
University, Anderson, SC, to Ron Myers, U. S. Environmental Protection Agency, Research
Triangle Park, NC, January 31, 1997.
20. Written communication from D. Lawler, State of Illinois Environmental Protection Agency,
Springfield, IL, to Ron Myers, U. S. Environmental Protection Agency, Research Triangle Park,
NC, March 24, 1997.
21. Written communication from B. Shrager, Midwest Research Institute, Gary, NC, to Ron Myers,
U. S. Environmental Protection Agency, Research Triangle Park, NC, April 28, 1997.
22. Shacklette, H.T. and Boerngen, J.B., Element Concentrations in Soils and Other Surficial Materials
of the Conterminous United States, U.S. Geological Survey Professional Paper 1270, U.S.
Government Printing Office, Washington, D.C., 1984.
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3. GENERAL DATA REVIEW AND ANALYSIS PROCEDURES
3.1 LITERATURE SEARCH AND SCREENING
Data for this investigation were obtained from a number of sources within the Office of Air Quality
Planning and Standards (OAQPS) and from outside organizations. The AP-42 background files located in
the Emission Factors and Inventory Group (EFIG) were reviewed for information on the industry, processes,
and emissions. The Factor Information and Retrieval (FIRE), Crosswalk/Air Toxic Emission Factor Data
Base Management System (XATEF), and VOC/PM Speciation Data Base Management System (SPECIATE)
data bases were searched by SCC code for identification of the potential pollutants emitted and emission
factors for those pollutants. A general search of the Air CHIEF CD-ROM also was conducted to supplement
the information from these data bases.
Information on the industry, including number of plants, plant location, and annual production
capacities, was obtained from the Census of Manufactures, and other sources. The Aerometric Information
Retrieval System (AIRS) data base also was searched for data on the number of plants, plant location, and
estimated annual emissions of criteria pollutants. A number of sources of information were investigated
specifically for emission test reports and data. A search of the Test Method Storage and Retrieval (TSAR)
data base was conducted to identify test reports for sources within the brick and structural clay product
manufacturing industry. Copies of these test reports were obtained from the files of the Emissions
Monitoring and Analysis Division (EMAD). The EPA library was searched for additional test reports. Using
information obtained on plant locations, State and Regional offices were contacted about the availability of
test reports. Publications lists from the Office of Research and Development (ORD) and Control Technology
Center (CTC) were also searched for reports on emissions from the brick and structural clay product
manufacturing industry. In addition, representative trade associations, including the Brick Institute of
America and the Brick Association of the Carolinas, were contacted for assistance in obtaining information
about the industry and emissions.
To screen out unusable test reports, documents, and information from which emission factors could
not be developed, the following general criteria were used:
1. Emission data must be from a primary reference:
a. Source testing must be from a referenced study that does not reiterate information from previous
studies.
b. The document must constitute the original source of test data. For example, a technical paper was
not included if the original study was contained in the previous document. If the exact source of the data
could not be determined, the document was eliminated.
2. The referenced study should contain test results based on more than one test run. If results from
only one run are presented, the emission factors must be down rated.
3. The report must contain sufficient data to evaluate the testing procedures and source operating
conditions (e.g., one-page reports were generally rejected).
A final set of reference materials was compiled after a thorough review of the pertinent reports,
documents, and information according to these criteria.
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3.2 DATA QUALITY RATING SYSTEM1
As part of the analysis of the emission data, the quantity and quality of the information contained in
the final set of reference documents were evaluated. The following data were excluded from consideration:
1. Test series averages reported in units that cannot be converted to the selected reporting units;
2. Test series representing incompatible test methods (i.e., comparison of EPA Method 5 front half
with EPA Method 5 front and back half);
3. Test series of controlled emissions for which the control device is not specified;
4. Test series in which the source process is not clearly identified and described; and
5. Test series in which it is not clear whether the emissions were measured before or after the control
device.
Test data sets that were not excluded were assigned a quality rating. The rating system used was that
specified by EFIG for preparing AP-42 sections. The data were rated as follows:
A—Multiple tests that were performed on the same source using sound methodology and reported in
enough detail for adequate validation. These tests do not necessarily conform to the methodology specified in
EPA reference test methods, although these methods were used as a guide for the methodology actually used.
B—Tests that were performed by a generally sound methodology but lack enough detail for adequate
validation.
C—Tests that were based on an untested or new methodology or that lacked a significant amount of
background data.
D—Tests that were based on a generally unacceptable method but may provide an order-of-
magnitude value for the source.
The following criteria were used to evaluate source test reports for sound methodology and adequate
detail:
1. Source operation. The manner in which the source was operated is well documented in the report.
The source was operating within typical parameters during the test.
2. Sampling procedures. The sampling procedures conformed to a generally acceptable
methodology. If actual procedures deviated from accepted methods, the deviations are well documented.
When this occurred, an evaluation was made of the extent to which such alternative procedures could
influence the test results.
3. Sampling and process data. Adequate sampling and process data are documented in the report,
and any variations in the sampling and process operation are noted. If a large spread between test results
cannot be explained by information contained in the test report, the data are suspect and are given a lower
rating.
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4. Analysis and calculations. The test reports contain original raw data sheets. The nomenclature
and equations used were compared to those (if any) specified by EPA to establish equivalency. The depth of
review of the calculations was dictated by the reviewer's confidence in the ability and conscientiousness of the
tester, which in turn was based on factors such as consistency of results and completeness of other areas of
the test report.
3.3 EMISSION FACTOR QUALITY RATING SYSTEM1
The quality of the emission factors developed from analysis of the test data was rated using the
following general criteria:
A = Excellent. Emission factor is developed primarily from A- and B-rated source test data
taken from many randomly chosen facilities in the industry population. The source category
population is sufficiently specific to minimize variability.
B = Above average. Emission factor is developed primarily from A- or B-rated test data from a
moderate number of facilities. Although no specific bias is evident, is not clear if the
facilities tested represent a random sample of the industry. As with the A rating, the source
category population is sufficiently specific to minimize variability.
C = Average. Emission factor is developed primarily from A-, B-, and C-rated test data from a
reasonable number of facilities. Although no specific bias is evident, it is not clear if the
facilities tested represent a random sample of the industry. As with the A rating, the source
category population is sufficiently specific to minimize variability.
D = Below average. Emission factor is developed primarily from A-, B- and C-rated test data
from a small number of facilities, and there may be reason to suspect that these facilities do
not represent a random sample of the industry. There also may be evidence of variability
within the source population.
E = Poor. Factor is developed from C- and D-rated test data from a very few number of
facilities, and there may be reason to suspect that the facilities tested do not represent a
random sample of the industry. There also may be evidence of variability within the source
category population.
The use of these criteria is somewhat subjective and depends to an extent upon the individual
reviewer. Details of the rating of each candidate emission factor are provided in Section 4.
REFERENCE FOR SECTION 3
1. Procedures for Preparing Emission Factor Documents EPA-454/R-95-015, Office of Air Quality
Planning and Standards, U. S. Environmental Protection Agency, Research Triangle Park, NC,
May 1997.
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4. REVIEW OF SPECIFIC DATA SETS
4.1 INTRODUCTION
Emission factors for brick manufacturing operations (grinding rooms, brick dryers, natural gas-,
coal-, and sawdust-fired tunnel kilns, and sawdust dryers) were developed using data from 28 test reports and
1 summary report. Five additional test reports, References 11, 16, and 26 through 28, were not used for
emission factor development for several reasons. The test methodology described in Reference 11 is not
valid. Insufficient process data are provided in Reference 16. Reference 26 provides summary data for
testing of a week-long batch kiln cycle, and three 1-hour test runs were conducted. This test did not
characterize emissions for the entire kiln cycle, and the data are not useful for emission factor development.
References 27 and 28 provide summary data for two tests conducted at the same facility (not the same kiln,
but a similar kiln) described in Reference 2. The data from References 27 and 28 are not used for emission
factor development because only summary data are provided, and the data are not consistent with the fully
documented data from Reference 2. Reviews of two additional documents, References 31 and 36, are also
included in this report, although the documents were not used for emission factor development.
In addition to the new information, the references from the 1986 AP-42 section were reviewed, and
the references that contain original test data are discussed in the following section. Emission factors for
structural clay product manufacturing were developed using data from two reports.
4.2 REVIEW OF SPECIFIC DATA SETS
4.2.1 Reference 1
This test report documents an emission test conducted on November 8-12, 1993, at the Belden Brick
Corporation Plant 6 in Sugarcreek, Ohio. The test was sponsored by EPA and was conducted to develop
emission factors for grinding and screening, brick drying, and brick firing operations. The grinding room was
tested for filterable PM and PM-10 emissions prior to and following the fabric filtration system that controls
grinding room emissions. A natural gas-fired brick dryer was tested for emissions of TOC, methane, and
ethane. A natural gas-fired tunnel kiln was tested for emissions of filterable PM, PM-10, condensible PM,
CO, NOX, SO2, CO2, HF, hydrochloric acid (HC1), chlorine (C12), TOC, methane, ethane, metals, and
speciated VOC and semi-volatile organic compounds (SVOC). All of the pollutants were measured using
EPA reference test methods.
The grinding room was tested for uncontrolled and controlled filterable PM and PM-10 emissions.
The inlet and outlet of the grinding room fabric filtration system were tested using EPA Method 5 and 201A
sampling trains. Three test runs were conducted at the fabric filter inlet, and two test runs were conducted at
the outlet. Only two runs were conducted at the outlet because light grain loadings necessitated long (6 to
7 hour) test runs. The inlet measurements were taken upstream of two small ducts that tied into the main duct
just before the baghouse, but the dust loading carried by these two small ducts is believed to be minimal in
comparison to the rest of the system. The average raw material moisture content (following the grinding
operations) was 3.9 percent, and the average silt content was 16.9 percent. These grinding room emission
data are assigned an A rating. Reference test methods were used, no problems were reported, and sufficient
detail was provided in the report. A mass balance (using the grinding room fabric filter catch) was performed
to determine uncontrolled filterable PM emissions from the grinding room, but the results of this test are
believed to be biased high. Therefore, the mass balance data are not rated for use in developing emission
factors.
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The brick dryer (heated with waste heat from the kiln cooling zone and a supplemental gas burner)
was tested for TOC, methane, and ethane emissions. The natural gas burner in the dryer was malfunctioning
during the testing. Therefore, the results of these tests are not used for emission factor development and the
data are not rated. However, Belden retested the dryer for TOC and CO emissions after the malfunctioning
burner was fixed, and the data from the retest are presented in Appendix F of this report. These data are
assigned a B rating because they are based on a single continuous test run.
Most of the data from the kiln test are assigned an A rating. The data for several of the organic
pollutants measured with the volatile organic sampling train (VOST) are assigned a B rating because the
measured concentrations for one or two test runs were either below the method quantitation limit or above the
calibration range. In such cases, the concentrations were estimated. Data for unvalidated organic compounds
measured with VOST and semi-VOST are downrated one letter grade. In addition, high background
concentrations of several metals (antimony, cadmium, cobalt, lead, and selenium) may have biased the metals
analysis. The data for these metals are downrated to C. Also, arsenic and beryllium were not detected during
any test run, and emissions of these metals are estimated as one-half of the detection limit. These data are
rated C.
After reviewing the test results, it became apparent that Belden is not a typical brick manufacturing
facility. The raw material is mined from a coal seam (in conjunction with coal mining activities) and contains
higher percentages of sulfur, several metals, and some organic pollutants than materials typically used for
manufacturing brick. Also, Belden uses natural gas from a well in combination with public utility natural
gas, and the gas may contain impurities. The emission data for SO2 and several metals, including chromium,
cobalt, mercury, and nickel, were unexpectedly higher than other available data for brick kilns. Therefore,
data for each pollutant were examined for potential biases caused by the atypical materials; much of the data
from this test were not used for emission factor development.
4.2.2 Reference 2
This test report documents an emission test conducted on July 26-31, 1992, at the General Shale
Products Corporation brick plant in Johnson City, Tennessee. The test was sponsored by EPA and was
conducted to develop emission factors for grinding and screening, brick drying, and brick firing operations.
The grinding room was tested for emissions of filterable PM and PM-10 emissions following the fabric
filtration system that controls grinding room emissions. The brick dryer, which is heated with waste heat
from the cooling section of the kiln, was tested for emissions of TOC, methane, and ethane. Kiln A (one of
two coal-fired tunnel kilns operating at the facility) was tested for emissions of filterable PM, PM-10,
condensible PM, CO, NOX, CO2, HF, TOC, methane and ethane, metals, and speciated VOC and SVOC.
The kiln was equipped with supplemental gas burners, which facilitate coal combustion.
All of the pollutants, except for methane and ethane, were measured using EPA reference test
methods. Methane and ethane emissions were quantified by modifying an EPA Method 25A sampling
system with an activated charcoal filter, which removed all hydrocarbons except for methane and ethane prior
to analysis. This modified Method 25A test was conducted before each Method 25A test run on the dryer,
and before and after each Method 25 A run on the kiln. Several of the compounds detected by the semi-
VOST and VOST were either below the method quantitation limit or above the calibration range. These
compounds include: chloromethane, trichlorfluoromethane, carbon disulfide, acetone, 2-butanone, benzene,
toluene, m-/p-xylene, 1,1-dichloroethane, dibenzofuran, 1,4-dichlorobenzene, 2-methylnaphthalene,
diethylphthalate, and butylbenzylphthalate. The values for these compounds were estimated and are
footnoted in the test report. In addition, emissions of several pollutants were not detected during one or more
test runs. Emissions for nondetect runs were estimated as one-half of the detection limit for each pollutant
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(for each run). These pollutants (number of nondetect runs) are: chloromethane (one run), carbon disulfide
(one run), chloroform (all three runs), vinyl acetate (all three runs), 1,1,1-trichloroethane (all three runs),
carbon tetrachloride (all three runs), trichloroethane (all three runs), tetrachloroethane (all three runs),
2-hexanone (all three runs), styrene (all three runs), 2-methylphenol (all three runs), dimethylphthalate (all
three runs), dibenzofuran (two runs), 1,4-dichlorobenzene (one run), butylbenzylphthalate (one run), and
di-n-octylphthalate (one run).
The grinding room was tested for filterable PM and PM-10 emissions. The grinding room fabric
filter exhaust stack was tested using EPA Method 5 and 201A sampling trains. The raw material moisture
content was between 8.1 and 10.8 percent, and the average silt content was about 17.1 percent. These data
are assigned an A rating. The reference test methods were used, no problems were reported, and sufficient
detail was provided.
Most of the data from the kiln and brick dryer tests are assigned an A rating. The data for TOC and
methane/ethane emissions from the kiln are assigned a B rating because the Run 3 methane/ethane
measurement was higher than the Run 3 TOC measurement. The data for several of the organic pollutants
measured by VOST are assigned a B rating because the measured concentrations in one or more test runs
were either below the method quantitation limit or above the calibration range. In such cases, the
concentrations were estimated. In addition, data for unvalidated compounds measured with the VOST and
semi-VOST are downrated one letter grade, data for compounds not detected in one of three test runs are
downrated one letter grade, and data for compounds not detected in two or three test runs are rated C.
4.2.3 Reference 3
This test report documents an emission test conducted on March 9, 1993 at the Chattahoochee Brick
Company in Atlanta, Georgia. The test was sponsored by General Shale Products Corporation and was
conducted to provide baseline emission data for emissions from brick kilns. Uncontrolled emissions of SO2,
NOX, CO, CO2, and total hydrocarbons from the kiln and the brick dryer were quantified using EPA Methods
6C, 7E, 10, 3 (with an Orsat gas analyzer), and 25A, respectively. A single 90-minute continuous test was
conducted, with monitor readings recorded every 30 seconds. The testing indicated that SO2, NOX, CO, and
CO2 are not emitted from the brick dryer, which is heated with waste heat from the cooling section of the kiln.
The primary fuel fired in the kiln was a low-sulfur (1.09 percent), low-ash (4.38 percent) coal, and
supplemental natural gas provided about 22 percent of the heat in the kiln. Data to determine both the green
brick feed and fired brick (production) process rates were provided in the report.
A rating of A was assigned to all of the test data. The report included adequate detail, the
methodology appeared to be sound, and no problems were reported.
4.2.4 Reference 4
This test report documents an emission test conducted on October 27 through November 6, 1992 at
the Pine Hall Brick Plant in Madison, North Carolina. The test was sponsored by EPA and was conducted to
develop emission factors for the primary crushing, grinding and screening, brick firing, and sawdust drying
operations. The primary crusher and the grinding room were tested for filterable PM and PM-10 emissions,
and two kilns and one sawdust dryer were tested for emissions of filterable PM, PM-10, condensible PM,
CO, NOX, CO2, total fluorides, HF, TOC, metals, and speciated VOC and SVOC. In addition, particle size
analyses were performed at the kiln and sawdust dryer outlets. Process data are provided in an attachment to
the report and are based on tons of material processed (primary crusher, grinding room) and tons of brick
produced (kiln and sawdust dryer). In the report, the sampling point at which the kiln emissions were tested
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is referred to as the sawdust dryer inlet because the sawdust dryer is heated using the kiln exhaust. The
sawdust dryer outlet A and outlet B results represent emissions from both the kiln and the sawdust dryer.
All of the pollutants were measured using EPA reference test methods. Several problems were noted
during the testing, including: (1) isokinetic problems encountered during the total fluoride testing at the kiln
and sawdust dryer outlets; (2) isokinetic problems with the first particle sizing run at the kiln outlet (four runs
were conducted); (3) the sawdust dryer outlet A NOX monitor exceeded the calibration drift limit during Run
3 of the multiple metals train and Runs 1 and 3 of semi-VOST and VOST; (4) in the analysis of the semi-
VOST and VOST samples, several of the detected compounds were either below the method quantitation
limit or above the calibration range (the values for these compounds were estimated and the results are
footnoted in the test report); (5) the impinger fractions for semi-VOST Runs 1 and 2 (outlet B) were
mislabeled during analysis; however, the two fractions were analyzed separately and found to be similar; and
(6) the first test on the primary crusher was not valid because air flow through the crusher was not measured
and the filter was not centered in the sampler.
The primary crusher was tested for total suspended particulate (TSP) and PM-10 emissions using
ambient monitors. The crusher was enclosed on the discharge side (except for the area immediately
surrounding the conveyor exit) and was completely open on the charging side. A total air flow meter was used
to approximate the air flow rate into the building at the conveyor exit side of the crusher. Flow rates were
calculated by multiplying the air flow meter reading (in feet) by the area of the face of the meter (in square
feet) and dividing by the total measurement time. These data are not rated for use in developing emission
factors because the air flow rates are approximated, and it is likely that additional air was flowing through the
building through the conveyor opening at the discharge side.
The grinding room was tested for filterable PM and PM-10 emissions. Emissions were tested by
ducting two of the three exhaust fans (located near the top of the building) to ground level, where EPA
Method 5 and 201A sampling trains were used to quantify emissions. The third exhaust fan was turned off
during testing. The raw material moisture content was between 13 and 14.2 percent, and the average silt
content was about 4.5 percent. The opening for the third exhaust fan was not covered during testing, and
during part of the first test run, a bay door was left open, possibly allowing PM emissions to leave the
building. These data are assigned a B rating. Reference test methods were used, no problems were reported,
and sufficient detail was provided. However, it is possible that emissions were exiting the grinding room
through the third exhaust fan opening throughout the test or through the bay door during the first run.
The kiln and sawdust dryer tests were conducted according to EPA reference test methods and most
of the data are assigned an A rating. The total fluoride data are not rated because the first run (outlet) was not
isokinetic, only one of the two outlet ducts was tested, a meter box malfunctioned during testing, and the
results were significantly lower than the HF test results (which are supported by the results of a mass balance
test conducted by Clemson University). The data for several of the organic pollutants measured with VOST
are assigned a B rating because the measured concentrations were either below the method quantitation limit
or above the calibration range. In such cases, the concentrations were estimated. In addition, data for
unvalidated compounds measured with the VOST and semi-VOST are downrated one letter grade. Data for
ketone emissions are assigned a C rating because ketone recovery from the VOST is erratic.
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4.2.5 Reference 5
This test report documents an emission test conducted on March 3, 1992 at Belden Brick Plant 3 in
Sugarcreek, Ohio. The test was sponsored by Belden Brick and was conducted for compliance purposes.
Uncontrolled emissions of filterable PM, SO2, NOX, and CO2 from the No. 1 kiln were quantified using EPA
Methods 5, 6, 7, and 3 (with an Orsat gas analyzer), respectively. Three test runs were conducted at the kiln
stack. The fuel fired in the kiln was natural gas. Process data were provided in the report, but the basis of
these data (feed or product) was not specified. The process data are assumed to represent fired brick
production.
A rating of B was assigned to all of the test data. The report included adequate detail, the
methodology appeared to be sound, and no problems were reported. However, the basis for the process data
is not specified in the report.
4.2.6 Reference 6
This test report documents an emission test conducted on October 17-19, 1990 at the General Shale
Products Corporation facility in Marion, Virginia. The test was sponsored by General Shale and was
conducted for compliance purposes. Uncontrolled emissions of filterable PM and CO2 from the kilns 6B and
28 were quantified using EPA Methods 5 and 3 (with a Fyrite gas analyzer), respectively. Three test runs
were conducted at each kiln stack. The primary fuel fired in the kiln was a low-sulfur (0.83 percent), low-ash
(2.86 percent) coal, and supplemental natural gas provided 16 percent of the heat for kiln 6B and 7.5 percent
for kiln 28. Data to determine the green brick (feed) rates for both kilns are provided in the report. General
Shale was contacted for the additional data (fired brick weight) needed to determine the brick production
rates. To determine the brick production rates, the green brick feed rates were multiplied by the ratios of the
weights of fired bricks and green bricks for the respective kilns, which were 0.833 (kiln 6B) and 0.813 (kiln
28).
A rating of A was assigned to the filterable PM test data, and a rating of C was assigned to the CO2
data. The report included adequate detail, the PM test methodology appeared to be sound, and no problems
were reported. The CO2 data are downrated to C because of the relative inaccuracy of Fyrite gas analyzers.
4.2.7 Reference 7
This test report documents an emission test conducted on October 16, 1990 at the General Shale
Products Corporation facility in Glascow, Virginia. The test was sponsored by General Shale and was
conducted for compliance purposes. Uncontrolled emissions of filterable PM and CO2 from kiln No. 21 were
quantified using EPA Methods 5 and 3 (with a Fyrite analyzer), respectively. Three test runs were conducted
at the kiln stack. The primary fuel fired in the kiln was a low-sulfur, low-ash coal (percentages of sulfur and
ash in the coal are not included in the report), and supplemental natural gas provided about 8 percent of the
heat for the kiln. Data to determine the green brick feed rates for the kiln are provided in the report. General
Shale was contacted for the additional data (fired brick weight) needed to determine the brick production
rates. To determine the brick production rates, the green brick feed rates were multiplied by the ratio of the
weights of a fired brick and a green brick, which was 0.778 for the test.
A rating of A was assigned to the filterable PM test data, and a rating of C was assigned to the CO2
data. The report included adequate detail, the PM test methodology appeared to be sound, and no problems
were reported. The CO2 data are downrated to C because of the relative inaccuracy of Fyrite gas analyzers.
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4.2.8 Reference 8
This test report documents an emission test conducted on July 21, 1989 at Belden Brick Plant 3 in
Sugarcreek, Ohio. The test was sponsored by Belden Brick and was conducted for compliance purposes.
Uncontrolled emissions of filterable PM, SO2, NOX, and CO2 from the No. 1 kiln were quantified using EPA
Methods 5, 6, 7, and 3 (Orsat), respectively. Three test runs were conducted at the kiln stack. The fuel fired
in the kiln was natural gas. The kiln tested is the same kiln as that discussed in Reference 5. Process data
were provided in the report, but the basis of these data (feed or product) was not specified. The process data
are assumed to represent fired brick production.
A rating of B was assigned to all of the test data. The report included adequate detail, the
methodology appeared to be sound, and no problems were reported. However, the basis for the process data
is not specified in the report.
4.2.9 Reference 9
This test report documents an emission test conducted on December 2, 1986 at the General Shale
Products Corporation facility in Mooresville, Indiana. The test was sponsored by General Shale and was
conducted for compliance purposes. Uncontrolled emissions of SO2 and CO2 from kiln No. 20 and the kiln
No. 20 brick dryer were quantified using EPA Methods 6 and 3 (with a Fyrite gas analyzer), respectively.
Normally, brick dryers are not expected to emit SO2 or CO2. Therefore, General Shale was contacted to
determine the cause of these emissions. Apparently, the dryer stack was venting emissions from the kiln
during the test. Therefore, kiln emissions are calculated as the sum of the dryer stack emissions and the kiln
stack emissions. Three test runs were conducted at the kiln stack and at the dryer stack. The fuel fired in the
kiln was a low-sulfur (1.05 percent), low-ash (3.35 percent) coal. Data to determine the green brick feed
rates for the kiln are provided in the report. General Shale was contacted for the additional data (fired brick
weight) needed to determine the brick production rates. To determine the brick production rates, the green
brick feed rates were multiplied by the ratio of the weights of a fired brick and a green brick, which was 0.792
for the test.
A rating of A was assigned to the SO2 test data, and a rating of C was assigned to the CO2 data. The
report included adequate detail, the SO2 test methodology appeared to be sound, and no problems were
reported. Because of the relative inaccuracy of Fyrite gas analyzers, the CO2 data are downrated to C.
4.2.10 Reference 10
This test report documents an emission test conducted on April 22, 1986 at the General Shale
Products Corporation facility in Knoxville, Tennessee. The test was sponsored by General Shale and was
conducted for compliance purposes. Uncontrolled emissions of filterable PM and CO2 from kiln No. 7B
were quantified using EPA Methods 5 and 3 (with a Fyrite gas analyzer), respectively. Three test runs were
conducted at the kiln stack. The fuel fired in the kiln was a low-sulfur (1.18 percent), low-ash (4.31 percent)
coal. Data to determine the green brick feed rates for the kiln are provided in the report. General Shale was
contacted for the additional data (fired brick weight) needed to determine the brick production rates. To
determine the brick production rates, the green brick feed rates were multiplied by the ratio of the weights of a
fired brick and a green brick, which was 0.895 for the test.
A rating of A was assigned to the filterable PM test data, and a rating of C was assigned to the CO2
data. The report included adequate detail, the filterable PM test methodology appeared to be sound, and no
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problems were reported. Because of the relative inaccuracy of Fyrite gas analyzers, the CO2 data are
downrated to C.
4.2.11 Reference 12
This test report documents an emission test conducted on October 11, 1983 at the General Shale
Products Corporation facility in Kingsport, Tennessee. The test was sponsored by General Shale and was
conducted for compliance purposes. Uncontrolled emissions of filterable PM and CO2 from kiln No. 15 were
quantified using EPA Methods 5 and 3 (with a Fyrite analyzer), respectively. Four test runs were conducted
at the kiln stack. The primary fuel fired in the kiln was a low-sulfur (0.79 percent), low-ash coal
(3.22 percent), and supplemental natural gas provided about 21 percent of the heat for the kiln. Data to
determine the green brick feed rates for the kiln are provided in the report. General Shale was contacted for
the additional data (fired brick weight) needed to determine the brick production rates. To determine the
brick production rates, the green brick feed rates were multiplied by the ratio of the weights of a fired brick
and a green brick, which was 0.837 for the test.
A rating of A was assigned to the filterable PM test data, and a rating of C was assigned to the CO2
data. The report included adequate detail, the PM test methodology appeared to be sound, and no problems
were reported. Because of the relative inaccuracy of Fyrite gas analyzers, the CO2 data are downrated to C.
4.2.12 Reference 13
This test report documents an emission test conducted on July 21, 1982 at the General Shale
Products Corporation facility in Kingsport, Tennessee. The test was sponsored by General Shale and was
conducted for compliance purposes. Emissions of filterable PM and CO2 following the kiln No. 29 fabric
filtration system were quantified using EPA Methods 5 and 3 (with a Fyrite analyzer), respectively. Three
test runs were conducted at the fabric filter outlet stack. The fuel fired in the kiln was a low-sulfur
(0.78 percent), low-ash coal (4.91 percent). Data to determine the green brick feed rates for the kiln are
provided in the report. General Shale was contacted for the additional data (fired brick weight) needed to
determine the brick production rates. To determine the brick production rates, the green brick feed rates were
multiplied by the ratio of the weights of a fired brick and a green brick, which was 0.818 for the test. In
addition to the kiln test, two filterable PM test runs were conducted at the outlet of the fabric filter that
controlled emissions from the coal crusher. Coal throughput data are not provided in the report, and the data
could not be used for emission factor development.
A rating of A was assigned to the filterable PM test data, and a rating of C was assigned to the CO2
data. The report included adequate detail, the PM test methodology appeared to be sound, and no problems
were reported. Because of the relative inaccuracy of Fyrite gas analyzers, the CO2 data are downrated to C.
4.2.13 Reference 14
This test report documents an emission test conducted on August 19, 1980 at the Chatham Brick and
Tile Company brick plant in Gulf, North Carolina. The test was sponsored by EPA for use in developing new
source performance standards. Two sawdust-fired kilns (one using natural gas for flashing) were tested for
CO2 emissions using EPA Method 3 (with an Orsat gas analyzer). In addition, a particle size analysis was
performed on emissions from the kiln that was not performing flashing. An Anderson Mark III cascade
impactor was used to perform two particle size tests. This cascade impactor is assumed to include a cyclone
prior to the impactor, like the impactor used in the Reference 15 emission test. The CO2 measurements did
4-7
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not include volumetric flow measurements for each test run; therefore, these data could not be used for
emission factor development.
The particle size data are assigned a B rating because only two test runs were performed. The report
included adequate detail, the test methodology appeared to be sound, and no problems were reported.
4.2.14 Reference 15
This test report documents an emission test conducted on January 9-12, 1980 at the Lee Brick and
Tile Company brick plant in Sanford, North Carolina. The test was sponsored by EPA for use in developing
new source performance standards. A coal-fired tunnel kiln was tested while processing both low-ash and
high-ash coal. However, only a single test run was conducted while high-ash coal was used, and these data
are not considered useful for emission factor development. During firing of low-ash coal, filterable PM and
condensible inorganic PM emissions were measured using three EPA Method 5 test runs on each of three kiln
stacks (north, south, and bottom stacks venting emissions from one kiln) and one brick dryer stack. In
addition, EPA Method 3 (with an Orsat gas analyzer) was used to quantify CO2 emissions during each PM
run, and a particle size analysis was performed at the north and south kiln stacks using a cascade impactor.
The cascade impactor includes a cyclone prior to the impactor. Sulfur dioxide and NOX emissions were
measured using single EPA Method 6 and 7 tests, respectively, at each kiln stack and the dryer stack.
Production rates are provided in the report.
The filterable PM, condensible inorganic PM, particle size, and CO2 data are assigned an A rating.
The report included adequate detail, the test methodology appeared to be sound, and no problems were
reported. The SO2 and NOX data are not rated because only one test run was conducted for each.
4.2.15 Reference 17
This test report documents a compliance test conducted on June 18, 1991, at the Acme Brick
Company facility in Sealy, Texas. A natural gas-fired brick kiln and a brick dryer were tested for filterable
PM (kiln only), total fluorides, SO2, and CO2 emissions using EPA Methods 5, 13, 6, and 3 (with Fyrite gas
analyzer), respectively. Dryer emissions were not controlled, and kiln emissions were controlled by a dry
packed bed scrubber (designed for HF control) that used 1/8 to 3/8 inch diameter limestone as the scrubbing
media. The scrubber is assumed to provide a small degree of PM removal in addition to effectively
controlling total fluorides emissions. The scrubber is assumed to have no significant effect on the SO2 and
CO2 emission measurements. The SO2 data from the dryer were added to the kiln SO2 data because SO2
emissions are not likely to result from brick drying. Process rates are provided (16 cars per day), and Acme
has specified that each kiln car carried 14,400 bricks that weighed 4 Ib each. The raw material processed at
this facility has an unusually high fluorine content, and the packed bed scrubber is unique in the brick
manufacturing industry in the United States.
The filterable PM, total fluorides, and SO2 data from this report are assigned an A rating. The test
methodology was sound, adequate detail about the testing was provided, and no problems were reported. The
CO2 data are assigned a C rating because of the relative inaccuracy of Fyrite gas analyzers.
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4.2.16 Reference 18
This test report documents an emission compliance test conducted on January 24, 1978 at the Lee
Brick and Tile Company brick plant in Sanford, North Carolina. A coal-fired tunnel kiln was tested for
filterable PM emissions using EPA Method 5. In addition, EPA Method 3 (with an unspecified gas analyzer)
was used to quantify CO2 emissions during the PM testing. A single test run was conducted on each of two
stacks, and process rates were provided (in tons of brick produced plus tons of coal used per hour). The
amount of coal used is not reported separately from the process rate. Therefore, actual brick production rates
cannot be calculated.
The data from this report are not rated because only one test run was conducted on each stack.
4.2.17 Reference 19
This test report documents an emission compliance test conducted on February 9, 1978 at the Lee
Brick and Tile Company brick plant in Sanford, North Carolina. A coal-fired tunnel kiln was tested for
filterable PM emissions using EPA Method 5. Three test runs were conducted on each of two stacks that
vented kiln emissions, and process rates were provided in tons of brick produced per hour.
The data from this report are assigned a C rating because the report does not contain any raw data
sheets, and the data presented are incomplete.
4.2.18 Reference 20
This test report documents an emission compliance test conducted on June 29, 1978 at the Lee Brick
and Tile Company brick plant in Sanford, North Carolina. A coal-fired tunnel kiln was tested for filterable
PM emissions using EPA Method 5. Three test runs were conducted on each of two stacks that vented kiln
emissions, and process rates were provided in tons of brick produced plus tons of coal burned per hour. The
amount of coal used is not reported separately from the process rate. Therefore, actual brick production rates
cannot be calculated.
The data from this report are not rated because the report presents only the mass emission rates and
production rates, and does not contain a summary of emission data or raw data sheets. Also, the production
rates are presented in units that are inconsistent with production rates provided in other reports.
4.2.19 Reference 21
This test report documents an emission compliance test conducted on July 18 and 19, 1979 at the
Chatham Brick and Tile Company brick plant in Sanford, North Carolina. A sawdust-fired tunnel kiln was
tested for filterable PM emissions using EPA Method 5. Three test runs were conducted on each of two
stacks that vented kiln emissions, and process rates were provided in tons of brick produced per hour.
Emissions of CO2 were measured during a single EPA Method 3 test run (gas analyzer not specified).
The PM data from this report are assigned an A rating. The test methodology was sound, adequate
detail is provided in the report, and no problems were reported. The CO2 data are not rated because only one
Method 3 test run was conducted.
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4.2.20 Reference 22
This reference documents the results of a test program conducted on October 17 and 18, 1995, at
Triangle Brick in Merry Oaks, North Carolina. Filterable PM, condensible inorganic and organic PM,
PM-10, metals, SO2, NOX, CO, THC, and CO2 emissions were measured using EPA Methods 5, 202, 201A,
6C, 7E, 10, 25A, and 3A (Orsat analyzer). The test was conducted to determine emission factors to be used
by the Brick Association of North Carolina.
During testing, the bricks produced included no facing material or other additives; consequently, the
emissions measured were a result of fuel combustion or were released from the raw material. Brick
production rates were recorded during testing, but are not included in the report. The test coordinator,
Mr. William Colby, was contacted to obtain the process rates. A copy of the contact report is included in the
final test report located in the AP-42 file.
The following pollutants were not detected during any test run: methane, beryllium, cobalt, and
mercury. Emissions of these pollutants are estimated as one-half of the detection limit for each pollutant and
each run.
Most of the data from this report are assigned an A rating. The test methodology was sound, no
problems were reported, and adequate detail was provided in the report. The data for pollutants that were not
detected are assigned a C rating because the emissions are estimated as described in the previous paragraph.
4.2.21 Reference 23
This reference includes a summary of emission testing conducted by the Center for Engineering
Ceramic Manufacturing at Clemson University and original test data sheets for several of the tests. The tests
were conducted at six facilities (seven kilns). All of the tests included HF or total fluoride measurements, and
some of the tests included measurements of HC1, SO2, SO3, and filterable PM. Reviews of the individual
tests are presented in the following paragraphs.
A test was conducted on November 8, 1995, at Boral Brick, Kiln No. 5, in Augusta, Georgia. A
natural gas-fired kiln was tested for HF and HC1 (EPA Method 26A), filterable PM (EPA Method 5), and
SO2/ SO3 (EPA Method 8) emissions. Sawdust was added to the brick bodies, but did not appear to effect
emissions. The data from this test are assigned a B rating. The test methodology was sound, no problems
were reported, and adequate (although not extensive) detail about the process and testing was provided.
A test was conducted on February 10 and 11, 1993, at Boral Brick in Phenix City, Alabama. A
natural gas-fired kiln was tested for HF and HC1 (EPA Method 26A), total fluoride (EPA Method 13B), and
SO2/ SO3 (EPA Method 8) emissions. The data from this test are assigned a C rating. The test methodology
was sound, but little documentation about the process and testing was provided.
A test was conducted from July 6 through 8, 1993, at Boral Brick (formerly Isenhour Brick) in
Salisbury, North Carolina. A sawdust-fired kiln (and sawdust dryer) was tested for HF and HC1 (EPA
Method 26A), filterable PM (EPA Method 5), and SO2/ SO3 (EPA Method 8) emissions. Although little
process information was provided, MRI and EPA visited this plant (in 1992) and are familiar with the
operations. The data from this test are assigned a B rating. The test methodology was sound, no problems
were reported, and adequate (although not extensive) detail about the process and testing was provided. The
filterable PM data from this test are not comparable to other available data because of the configuration of
the kiln and sawdust dryer.
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A test was conducted from July 6 through 8, 1993, at Endicott Clay Products in Fairbury, Nebraska.
A brick kiln (unspecified fuel) was tested for total fluoride (EPA Method 13B) emissions. The data from this
test are assigned a C rating. The test methodology was sound, but little documentation about the process and
testing was provided.
A test was conducted on August 31 and September 1, 1993, at Redlands Brick in East Windsor,
Connecticut. A natural gas-fired kiln was tested for HF and HC1 (EPA Method 26A) and SO2/ SO3 (EPA
Method 8) emissions. The data from this test are assigned a C rating. The test methodology was sound, but
little documentation about the process and testing was provided.
A test was conducted on December 20, 1994, at Richtex Brick, Plant No. 4 in Columbia, South
Carolina. A natural gas-fired brick kiln was tested for total fluoride (EPA Method 13B) emissions. All of
the test runs were between 114 percent and 116 percent isokinetic, but the average emission from the test are
consistent with total fluoride measurements from other facilities. The data from this test are assigned a C
rating because of the isokinetic variation. Adequate documentation about the process and testing was
provided.
A test was conducted at Richtex Brick, Plant No. 2, in Columbia, South Carolina. A coal-fired kiln
was tested for HF (EPA Method 26A) emissions. Other pollutants may have been measured, but original
data sheets were not available for this test. The data from this test are assigned a C rating. The test
methodology was sound, but no documentation about the process and testing was provided.
A test was conducted at Richtex Brick, Plant No. 4, in Columbia, South Carolina. A natural gas-
fired kiln was tested for HF (EPA Method 26A) emissions. Other pollutants may have been measured, but
original data sheets were not available for this test. The summary document states that this was a special test
to reduce HF emissions. The data from this test are not rated because the process was modified to reduce
emissions, but no documentation of the modifications or testing was provided.
4.2.22 Reference 24
This reference documents measurements of uncontrolled filterable PM, total fluorides, SO2, and CO2
emissions from a natural gas-fired tunnel kiln used to manufacture structural clay tile. The test was
conducted in September 1993 to demonstrate compliance with local regulations. Filterable PM, total
fluorides, SO2, and CO2 emissions were measured using EPA Methods 5, 13B, 6, and 3 (with Orsat analyzer
for CO2 analysis), respectively. Process rates were provided on the basis of production.
The manufacturing process consists of forming tile from a clay blend, spraying a color pigment on
the outside surface, drying the tile to a moisture content of 5 to 6 percent, then firing the tile in a tunnel kiln at
a temperature of about 1120°C (2050°F). The kiln cycle (tile retention time in the kiln) was 73 hours. The
sulfur content of the unfired tile averages about 0.19 percent at this facility.
The data from this report are assigned a B rating. The test methodology was sound and no problems
were reported, but the report did not contain sufficient detail to warrant a higher rating.
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4.2.23 Reference 25
This reference documents measurements of uncontrolled filterable PM, SO2, and CO2 emissions
from a natural gas-fired tunnel kiln used to manufacture structural clay tile. The test was conducted in
February 1988 to demonstrate compliance with local regulations. Filterable PM, SO2, and CO2 emissions
were measured using EPA Methods 5, 6, and 3 (with Orsat analyzer for CO2 analysis), respectively. Process
rates were provided on the basis of production. No other process information is provided in the report.
The data from this report are assigned a B rating. The test methodology was sound and no problems
were reported, but the report did not contain sufficient detail to warrant a higher rating.
4.2.24 Reference 29
This reference documents emission tests conducted on several different processes at Interstate Brick
in West Jordan, Utah. The tests were conducted on December 5-7, 1994. Emissions of PM-10 were
measured at the primary crusher fabric filter outlet and the Extrusion Line 3 and Line 4 fabric filter outlets.
Emissions of SO2, NOX, and CO2 were measured at the Tunnel Kiln No. 3 scrubber inlet and the Tunnel Kiln
No. 4 scrubber inlet. Emissions of filterable PM, condensible organic PM, condensible inorganic PM,
PM-10, total fluorides, SO2, NOX, and CO2 were measured at the Tunnel Kiln No. 4 scrubber outlet. All of
the tests included three test runs using EPA reference test methods.
The primary crusher test runs were all about 150 percent isokinetic, and the acceptable limit of
isokinetic variation for EPA Method 201A is ±20 percent. High isokinetics indicate that the emission
measurements are probably biased low. Because of this potential bias, these data are assigned a D rating and
should be considered a low estimate of PM-10 emissions from fabric filter-controlled primary crushers. A
process rate of 100 tons per hour of raw material throughput was recorded during testing.
The extrusion lines at Interstate Brick are controlled by fabric filters. Particulate matter emissions
are primarily a result of a material drop point prior to the pug mill. Additives, such as manganese dioxide
(325 mesh size) and barium carbonate, are sometimes added to the mixture and may contribute to PM
emissions. Two of the three Extrusion Line 3 test runs were slightly above 120 percent isokinetic (Run 1~
123 percent, Run 3—128 percent). However, the emission measurements from these two runs are comparable
to the measurements during Run 2, which met the isokinetic requirements of Method 201 A. Because no bias
is indicated, these data are assigned a B rating. A process rate of 21.9 tons per hour of material processed
was recorded during testing.
All of the three Extrusion Line 4 test runs were above 170 percent isokinetic. The emission
measurements from this test are slightly lower than the measurements from the Line 3 test discussed above.
However, the isokinetics indicate that a large bias is possible, and the data are assigned a D rating. A process
rate of 21.9 tons per hour of material throughput was recorded during testing.
The test conducted at the Tunnel Kiln No. 3 scrubber inlet is not valid because a letter provided by
Interstate Brick states that the volumetric flow rates measured during the test are incorrect.
Tunnel Kiln No. 4 is a natural gas-fired kiln equipped with a medium-efficiency scrubber designed to
remove SO2 and fluoride emissions from the kiln exhaust. The scrubber uses a soda-ash/water solution
(maintained at pH 7) as the scrubbing media. A process rate of 12 tons per hour of fired brick produced was
recorded during testing. The average sulfur and fluorine contents of the unfired brick produced by Interstate
Brick are 0.0866 percent weight and 0.0944 percent weight. The Tunnel Kiln No. 4 test data are assigned an
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A rating. The test methodology was sound, the report contains sufficient detail, and no problems were
reported.
4.2.25 Reference 30
This reference documents an emission test conducted on Tunnel Kiln No. 3 at Interstate Brick in
West Jordan, Utah. The testing was conducted on October 31, 1995. Emissions of filterable PM,
condensible organic PM, condensible inorganic PM, total fluorides, SO2, NOX, CO, and CO2 were measured
at the kiln scrubber inlet and outlet. All of the tests included three test runs using EPA reference test
methods.
Tunnel Kiln No. 3 is a natural gas-fired kiln equipped with a high-efficiency packed tower type
scrubber designed to remove SO2 and fluoride emissions from the kiln exhaust. The scrubber uses a soda-
ash/water solution as the scrubbing media. A process rate of 13.2 tons per hour of fired brick produced was
recorded during testing. The average sulfur and fluorine contents of the unfired brick produced by Interstate
Brick are 0.0866 percent weight and 0.0944 percent weight. The test data are assigned an A rating. The test
methodology was sound, the report contains sufficient detail, and no problems were reported.
4.2.26 Reference 31
This reference is Exhibit A provided by the BIA following the (December 1996 to February 1997)
external review of the draft background report and AP-42 Section 11.3. The document provides an estimate
of uncontrolled PM emissions from grinding rooms. The estimate is based on data obtained by EPA during
the November 1993 emission test conducted at Belden Brick. Ambient PM monitors were stationed upwind
and downwind of the grinding room, and inside the grinding room. The document estimates the percentage of
grinding room PM emissions that leave the building by subtracting the upwind (background) concentration
from the downwind concentration, and dividing the difference by the inside concentration. The calculated
percentage then was multiplied by the "uncontrolled" emission rate of the grinding room (measured at the
inlet of the fabric filter that controls grinding room emissions), to calculate an emission rate for PM the leaves
the building.
The methodology presented is somewhat similar to the upwind-downwind method of sampling
fugitive PM. The upwind-downwind method requires the use of sampling instruments at a minimum of two
downwind distances and three crosswind distances. The number of required upwind instruments depends on
the degree of isolation of the emission source (i.e., the absence of interference from other sources upwind).
The net downwind concentrations (i.e., downwind minus upwind) are used as input to dispersion equations to
backcalculate the PM emission rate required to generate the pollutant concentration measured. A number of
meteorological parameters must be concurrently reported for input to the dispersion equation. At a minimum,
the wind direction and speed must be recorded on-site.
The monitoring conducted upwind and downwind of the Belden Brick grinding room was conducted
for background information purposes and was not designed to calculate emission rates from the building. In
particular, meteorological data were not collected during the test, and the concentrations measured by only
one downwind monitor cannot be assumed to represent the entire plume emanating from the grinding
operations. Therefore, the data presented are not rated and are not used for emission factor development.
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4.2.27 Reference 32
This reference is Exhibit B provided by the BIA following the (December 1996 to February 1997)
external review of the draft background report and AP-42 Section 11.3. The document is a test report that
documents emission testing conducted on a sawdust-fired brick kiln at Boral Bricks, Isenhour Division, in
Salisbury, NC, on October 6, 1995. Tests for CO and CO2 were conducted at two stacks that vent emissions
from the No. 6 kiln and a third stack that vents emissions from the sawdust dryer (which is heated with a
portion of the kiln exhaust). The sawdust dryer exhaust was ducted to a cyclone prior to the exhaust stack.
Three test runs were conducted at each stack, and EPA reference test methods were used. The results of the
three tests were summed to determine the total emissions from the kiln and sawdust dryer. Fired brick
production rates are included in the report.
The data from this report are assigned an A rating. The test methodology was sound, adequate detail
was provided, and no problems were reported.
4.2.28 Reference 33
This reference includes Exhibits C and D provided by the BIA following the (December 1996 to
February 1997) external review of the draft background report and AP-42 Section 11.3. The document is a
test report that documents emission testing conducted on two natural gas-fired brick kilns at Boral Bricks,
Inc., in Smyrna, Georgia, on August 27 and 28, 1996. Emissions of filterable PM, total fluorides, TOC,
methane (not detected during any test run), SO2, CO, NOX, and CO2 at the exhaust stacks of tunnel kiln
Nos. 1 and 2. All of the tests included three valid runs using EPA reference test methods (Method 13B for
total fluorides). Fired brick production rates are provided in an attachment to the report.
Several mistakes were found in the Method 25A test data for TOC emissions. In the report, the
concentrations were not corrected to a dry basis before calculating the emission rates. Also, the first reading
for Run 1 on Kiln No. 2 was 7 ppm on the data recorder, but was recorded as zero in the calculations. These
errors were corrected before these data were used for emission factor development. The TOC emission rates
presented in this background report differ from the emission rates presented in the report because of the
corrections that were made. Also, the TOC data were reported "as carbon" in the report and were converted
to an "as propane" basis for use in developing emission factors.
The data from this report are assigned an A rating. The test methodology was sound, adequate detail
was provided, and no problems were reported.
4.2.29 Reference 34
This reference is Exhibit E provided by the BIA following the (December 1996 to February 1997)
external review of the draft background report and AP-42 Section 11.3. The document is a test report that
documents emission testing conducted on two natural gas-fired brick kilns at Boral Bricks, Inc., in
Henderson, TX, on February 15, 1996. Emissions of filterable PM, condensable inorganic PM, total
fluorides, SO2, SO3, NOX, and CO2 at the exhaust stack of the dry scrubber that controls emissions from
tunnel kiln Nos. 1 and 2. All of the tests included three valid runs (six CO2 runs) using EPA reference test
methods (Method 13B for total fluorides). Fired brick production rates are provided in the report.
The data from this report are assigned an A rating. The test methodology was sound, adequate detail
was provided, and no problems were reported.
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4.2.30 Reference 35
This reference is Exhibit F provided by the BIA following the (December 1996 to February 1997)
external review of the draft background report and AP-42 Section 11.3. The document is a test report that
documents emission testing conducted on two natural gas-fired brick kilns at Boral Bricks, Inc., in
Henderson, TX, on February 15, 1996. Emissions of filterable PM, condensable inorganic PM, total
fluorides, SO2, SO3, NOX, and CO2 at the exhaust stack of the dry scrubber that controls emissions from
tunnel kiln Nos. 1 and 2. Total fluoride emissions were also measured prior to the scrubber. All of the tests
included three valid runs using EPA reference test methods (Method 13B for total fluorides). Fired brick
production rates are provided in an attachment to the report. The scrubber demonstrated a fluoride removal
efficiency of about 93.5 percent during the test.
The data from this report are assigned an A rating. The test methodology was sound, adequate detail
was provided, and no problems were reported.
4.2.31 Reference 36
This reference is Exhibit G provided by the BIA following the (December 1996 to February 1997)
external review of the draft background report and AP-42 Section 11.3. The document is a memo
summarizing the approach suggested for all Boral plants in estimating emissions from pneumatic control
devices in operation. It suggests assuming a constant exhaust grain loading for pneumatic devices. This
memo also states that if operations are uncontrolled, emissions should be based on production rates (draft
AP-42 factor) and should incorporate a building removal efficiency where applicable.
For emission inventory purposes, an emission factor that is associated with production is needed to
estimate emissions from the industry as a whole. For a specific facility that needs to estimate emissions from
grinding rooms, the proposed method should provide a better estimate than the AP-42 emission factor. The
information from this memo was not used for emission factor development.
4.2.32 Reference 37
This reference is Exhibit H provided by the BIA following the (December 1996 to February 1997)
external review of the draft background report and AP-42 Section 11.3. The document is a test report that
documents emission testing conducted on a sawdust-fired brick kiln at Statesville Brick Company, in
Statesville, North Carolina, on November 29, 1994. Tests for CO and CO2 were conducted at a stack that
vents emissions from the No. 6 kiln and a stack that vents emissions from the sawdust dryer (which is heated
with a portion of the kiln exhaust). The sawdust dryer exhaust was ducted to a cyclone prior to the exhaust
stack. Three test runs were conducted at each stack, and EPA reference test methods were used. The results
of the three tests were summed to determine the total emissions from the kiln and sawdust dryer. Fired brick
production rates are included in the report.
The data from this report are assigned an A rating. The test methodology was sound, adequate detail
was provided, and no problems were reported.
4.2.33 Reference 38
This reference documents and emission testing conducted on the tunnel kiln and brick dryers at
Marseilles Brick Venture, Ltd., in Marseilles, Illinois, on August 29 and 30, 1994. The brick dryers are
independent tunnels that are each about 200 ft long and are heated with waste heat from the kiln cooling zone
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and supplemental gas burners. The raw material used to form the bricks included 17 percent shale and 83
percent fire clay mixture. The tunnel kiln is a 498 ft natural gas-fired kiln that holds 36 kiln cars. The
cooling zone includes a rapid cool zone where the brick is cooled from approximately 1930°F to about
1300°F by injecting ambient air directly on the brick. The kiln and dryers were tested for filterable PM, NOX,
CO, CO2, TOC, SO2, and SO3 emissions. Three test runs were conducted for each pollutant and EPA
reference test methods were used. During testing, the kiln was operating on a 15 car per day production
schedule; this equates to 11.97 tons per hour of fired brick produced. For the dryers, the process rate was
estimated using the assumption that each dryer provided half of the brick that was produced. Sulfur dioxide,
TOC, and NOX emissions were not detected during the dryer tests (SO2 and TOC were each detected by one
of six dryer test runs). Although SO3 was detected during the dryer tests, the data were added to the kiln SO3
data because SO3 emissions are not likely to result from brick drying.
The data from this report are assigned an A rating. The test methodology was sound, adequate detail
was provided, and no problems were reported.
4.2.34 Reference 39
This reference documents and emission testing conducted on the tunnel kiln and brick dryers at
Marseilles Brick Venture, Ltd., in Marseilles, Illinois, on May 10 and 11, 1994. The brick dryers are
independent tunnels that are each about 200 ft long and are heated with waste heat from the kiln cooling zone
and supplemental gas burners. The raw material used to form the bricks included 80 percent shale and 20
percent fire clay mixture. The tunnel kiln is a 498 ft natural gas-fired kiln that holds 36 kiln cars. The
cooling zone includes a rapid cool zone where the brick is cooled from approximately 1930°F to about
1300°F by injecting ambient air directly on the brick. The kiln and dryers were tested for filterable PM, NOX,
CO, CO2, TOC, SO2, and SO3 emissions. Three test runs were conducted for each pollutant and EPA
reference test methods were used. During testing, the kiln was operating on a 12 car per day production
schedule; this equates to 9.58 tons per hour of fired brick produced. For the dryers, the process rate was
estimated using the assumption that each dryer provided half of the brick that was produced. Sulfur dioxide
emissions were not detected during the dryer tests. Although SO3 was detected during four of six dryer test
runs, the data were added to the kiln SO3 data because SO3 emissions are not likely to result from brick
drying.
The data from this report are assigned an A rating. The test methodology was sound, adequate detail
was provided, and no problems were reported.
4.2.35 Review of FIRE and SPECIATE Data Base Emission Factors
The FIRE and SPECIATE data bases do not contain any new emission factors for brick and
structural clay product manufacturing operations.
4.3 DEVELOPMENT OF CANDIDATE EMISSION FACTORS
Emission factors for grinding and screening, brick dryers, coal-fired kilns, natural gas-fired kilns,
sawdust-fired kilns, and sawdust-fired kilns followed by sawdust dryers were developed using data from the
references described in Section 4.2 of this document. These data are presented in Table 4-1, the emission
factor data combination is shown in Table 4-2, and a summary of the candidate emission factors is presented
in Table 4-3. Particle size distribution data are shown in Tables 4-4 and 4-5. Sections 4.3.1 through 4.3.13
present detailed descriptions, by pollutant, of the data combination and emission factor
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TABLE 4-1. SUMMARY OF TEST DATA FOR BRICK AND STRUCTURAL CLAY
PRODUCT MANUFACTURING51
Source
Grinding roomb
Grinding room
Grinding roomb
Grinding room with
fabric filterb
Grinding room with
fabric filterb
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Pollutant
Filterable PM
Filterable PM- 10
Filterable PM
Filterable PM
Filterable PM- 10
Arsenic0
Beryllium0
Cadmium
Chromium
Cobalt
Mercury
Manganese
Nickel
Lead
Antimony
Selenium
Chloromethane
Chloroethane
lodomethane
Acetone
Carbon disulfide
2-butanone
1,1,1-Trichloroethane
Benzene
2-Hexanone
Tetrachloroethene
Toluene
Ethylbenzene
Styrene
m-/p-Xylene
o-Xylene
Phenol
1 ,4-dichlorobenzene
No. of
test runs
o
3
3
2
2
2
o
J
3
o
5
3
o
J
3
o
5
3
o
J
3
o
5
3
o
J
3
o
5
3
o
J
3
o
5
3
o
J
3
o
5
3
o
J
3
o
3
3
Data
rating
A
A
NR
A
A
C
C
C
A
C
A
A
A
C
C
C
B
B
B
C
B
C
B
B
C
A
B
B
B
B
B
A
B
Emission factor
range, Ib/ton
5.4-10.5
0.51-0.55
16-18
0.0043-0.0061
0.0011-0.0012
1.7xlO-5-1.9xlO-5
3.4xlO-7-3.6xlQ-7
1.0xlO-5-5.7xlO-5
0.0035-0.0151
5.2xlO-5-0.00020
7.0xlO-5-0.00023
0.00043-0.0013
0.0017-0.0082
6.3xlO-5-9.8xlQ-5
1.4xlO-5-2.7xlQ-5
0.00027-0.00051
9.0xlQ-5-0.0017
1.9xlO-6-0.0013
1.4xlQ-5-0. 00019
0.0012-0.0026
2.7xlO-5-5.3xlQ-5
0.00011-0.00034
6.6xlO-7-8.3xlQ-6
0.0012-0.0045
3.0xlQ-6-0. 00015
4.7xlO-7-4.1xlQ-6
0.00012-0.00018
3.6xlO-5-5.5xlQ-5
2.6xlO-6-4.7xlQ-5
5.5xlO-5-8.0xlQ-5
4.7xlO-5-6.9xlQ-5
6.3xlQ-5-0. 00010
3.7xlO-5-7.0xlQ-5
Average emission
factor, Ib/ton
8.5
0.53
17
0.0052
0.0011
l.SxlO'5
3.4xlO'7
S.SxlO'5
0.0075
0.00011
0.00016
0.00073
0.0042
7.9xlO'5
2.2xlO'5
0.00036
0.00067
0.00057
9.3xlO'5
0.0017
4.1X10'5
0.00022
4.7xlO'6
0.0029
8.5xlO'5
2.8xlO'6
0.00016
4.4xlO'5
2.0xlO'5
6.7xlO'5
5.8xlO'5
8.6X10'5
4.8xlO'5
Ref
No.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4-17
-------
TABLE 4-1. (continued)
Source
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Brick dryer with
supplemental gas
burner
Brick dryer with
supplemental gas
burner
Grinding room with
fabric filterb
Grinding room with
fabric filterb
Brick dryer-waste heat
Brick dryer-waste heat
Brick dryer-waste heat
Coal-fired kilng
Coal-fired kilng
Coal-fired kilng
Pollutant
Naphthalene
2-methylnaphthalene
Diethylphthalate
Di-n-butylphthalate
Butylbenzylphthalate
Bis(2-ethylhexy)phthalate
SO2
NOX
CO
C02
TOC as methane
Methane
Filterable PMd
Filterable PM6
Filterable PMf
Filterable PM- 10
Condensible inorganic PM
Condensible organic PM
Hydrogen fluoride
Hydrochloric acid
Chlorine
TOC as methane
CO
Filterable PM
Filterable PM- 10
TOC as propane
Methane/ethane as propane
TNMOC as propane
Filterable PM
Filterable PM- 10
Condensible inorganic PM
No. of
test runs
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
i
i
o
3
3
3
-\
^
3
6
3
-\
5
Data
rating
C
B
B
B
B
C
A
A
A
A
A
A
A
A
B
A
A
A
A
A
A
B
B
A
A
A
A
A
A
A
A
Emission factor
range, Ib/ton
4.6xlO-5-8.8xlQ-5
3.7xlO-5-8.0xlQ-5
0.00013-0.00041
0.00010-0.00022
1.5xlO-5-2.2xlQ-5
0.00059-0.0037
2.4-3.3
0.71-1.0
1.0-1.2
720-830
0.050-0.10
0.072-0.11
0.35-0.46
0.32-0.65
0.23-0.35
0.066-0.26
2.9-3.3
0.18-1.1
0.27-0.32
0.017-0.020
0.0012-0.0016
NA
NA
0.0042-0.012
0.0028-0.0093
0.058-0.062
0.023-0.034
0.026-0.039
0.62-0.76
0.38-0.51
0.067-0.19
Average emission
factor, Ib/ton
e.SxlO'5
5.7X10'5
0.00024
0.00014
l.SxlO'5
0.0020
3.0
0.91
1.1
770
0.081
0.084
0.42
0.47
0.30
0.13
3.1
0.51
0.30
0.018
0.0013
0.18
0.44
0.0072
0.0052
0.060
0.028
0.032
0.67
0.45
0.12
Ref
No.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
4-18
-------
TABLE 4-1. (continued)
Source
Coal-fired kiln§
Coal-fired kilng
Coal-fired kiln§
Coal-fired kilng
Coal-fired kiln§
Coal-fired kilng
Coal-fired kiln§
Coal-fired kilng
Coal-fired kiln§
Coal-fired kilng
Coal-fired kiln§
Coal-fired kilng
Coal-fired kiln§
Coal-fired kilng
Coal-fired kiln§
Coal-fired kilng
Coal-fired kiln§
Coal-fired kilng
Coal-fired kiln§
Coal-fired kilng
Coal-fired kiln§
Coal-fired kilng
Coal-fired kiln§
Coal-fired kilng
Coal-fired kiln§
Coal-fired kilng
Coal-fired kiln§
Coal-fired kilng
Coal-fired kiln§
Coal-fired kilng
Coal-fired kiln§
Coal-fired kilng
Coal-fired kiln§
Coal-fired kilng
Pollutant
Condensible organic PM
C02
Antimony
Arsenic
Beryllium
Cadmium
Chromium
Lead
Manganese
Mercury
Nickel
Phosphorus
Selenium
CO
NOX
Hydrogen fluoride
TOC as propane
Methane/ethane as propane
Chloromethaneh
Bromomethane
Trichlorofluoromethane
Carbon disulfide
Acetone
Methylene chloride
Chloroform0
Vinyl acetate0
2-butanone
1,1,1 -trichloroethanec
Carbon tetrachloridec
Benzene
Trichloroethanec
Toluene
Tetrachloroethanec
2-hexanonec
No. of
test runs
o
3
9
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
J
3
Data
rating
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
B
B
B
A
B
C
C
C
C
C
C
C
C
B
C
C
C
C
Emission factor
range, Ib/ton
0.029-0.068
210-300
1.3xlO-5-1.5xlO-5
1.3xlO-4-1.4xlQ-4
1.4xlO-5-1.7xlO-5
2.2xlO-6-4.3xlQ-6
7.2xlO-5-8.7xlQ-5
7.7xlO-5-9.1xlQ-5
4.5xlO-5-4.8xlQ-5
8.8xlO-5-1.0xlQ-4
1.6xlO-4-2.0xlQ-4
5.3xlO-4-5.8xlQ-4
4.2xlO-4-5.2xlQ-4
0.87-0.94
0.66-0.75
0.060-0.24
0.066-0.23
0.094-0.11
4.8xlO-5-1.7xlQ-4
2.2xlO-5-2.6xlQ-5
3.5xlO-6-3.0xlQ-5
5.0xlO-8-3.4xlQ-6
3.9xlO-4-9.3xlQ-4
0-2.4xlO'6
NA
NA
2.0xlO-4-2.9xlQ-4
NA
NA
2.8xlO-4-3.0xlQ-4
NA
2.0xlO-4-3.1xlQ-4
NA
NA
Average emission
factor, Ib/ton
0.048
270
1.4xlO'5
l.SxlO'4
1.6X10'5
S.SxlO'6
7.8X10'5
8.6X10'5
4.7X10'5
9.6X10'5
1.7xlO'4
5.5xlO'4
4.6xlO'4
0.90
0.71
0.13
0.14
0.10
l.lxlO'4
2.4xlO'5
1.4xlO'5
2.3X10'6
6.8xlO'4
S.OxlO'7
BDL(1.0xlQ-7)
BDL(1.0xlQ-7)
2.5xlO'4
BDL(1.7xlQ-5)
BDL(1.0xlQ-7)
2.9xlO'4
BDL(1.0xlQ-7)
2.5xlO'4
BDL(1.0xlQ-7)
BDL (8.2xlQ-7)
Ref
No.
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
4-19
-------
TABLE 4-1. (continued)
Source
Coal-fired kiln§
Coal-fired kilng
Coal-fired kiln§
Coal-fired kilng
Coal-fired kiln§
Coal-fired kilng
Coal-fired kiln§
Coal-fired kilng
Coal-fired kiln§
Coal-fired kilng
Coal-fired kiln§
Coal-fired kilng
Coal-fired kiln§
Coal-fired kilng
Coal-fired kiln§
Coal-fired kilng
Coal-fired kiln§
Coal-fired kilng
Coal-fired kiln§
Coal-fired kilng
Coal-fired kiln§
Brick dryer-waste heat
Brick dryer-waste heat
Coal-fired kilng
Coal-fired kiln§
Coal-fired kilng
Coal-fired kiln§
Coal-fired kilng
Primary crusher*3
Grinding room
Grinding roomb
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Pollutant
Ethylbenzene
M-/p-xylene
O-xylene
Styrenec
Chloroethane
1 , 1 -dichloroethane
Chlorobenzene
Phenol
Naphthalene
2-methylphenolc
Dimethylphthalatec
Dibenzofuran1
Di-n-butylphthalate
Bis(2-ethylhexy)phthalate
1 ,4-dichlorobenzeneh
Isophorone
Benzoic acid
2-methylnaphthalene
Diethylphthalate
Butylbenzylphthalateh
Di-n-octylphthalateh
SO2
TOC as propane
C02
S02k
NOX
CO
TOC as propane
Filterable PM- 10
Filterable PM
Filterable PM- 10
Filterable PM
Filterable PM- 10
Condensible inorganic PM
No. of
test runs
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
i
i
i
i
i
i
i
2
3
o
3
3
o
J
3
Data
rating
B
C
B
C
B
C
B
A
A
C
C
C
A
C
C
B
B
C
C
C
C
A
A
A
A
A
A
A
NR
B
B
A
A
A
Emission factor
range, Ib/ton
1.8xlO-5-2.7xlO-5
9.2xlO-5-1.8xlQ-4
3.6xlO-5-6.3xlQ-5
NA
1.0xlO-5-1.4xlO-5
7.7xlO-7-1.3xlO-5
1.4xlO-5-2.4xlQ-5
0-5.7xlQ-5
0-1.7xl(r5
NA
NA
2.9xl(T7-4.2xlCr7
0-0
0-1.2X10'4
6.9xlO-7-4.8xlQ-6
l.lxlO-6-8.7xlQ-5
1.6xlO-4-3.9xlQ-4
1.3xlO-6-2.5xlQ-6
7.9xlO-7-2.4xlQ-6
1.2xl(T6-1.3xlCr6
7.9xlO-6-1.4xlQ-5
NA
NA
NA
NA
NA
NA
NA
9.3xlO-8-1.3xlO-7
0.016-0.031
0.0019-0.0032
0.28-0.34
0.20-0.22
0.14-0.23
Average emission
factor, Ib/ton
2.1X10'5
l.SxlO'4
4.7xlO'5
BDL(1.0xlQ-7)
l.lxlO'5
S.OxlO'6
2.1X10'5
S.SxlO'5
6.9xlO'6
BDL (2.2xlQ-6)
BDL(7.8xlQ-7)
3.6xlO'7
0
4.9X10'5
3.2X10'6
S.OxlO'5
2.5xlO'4
1.7X10'6
1.4xlO'6
1.2X10'6
1.2X10'5
0
0.036
300
1.2
0.30
0.70
0.011
l.lxlO'7
0.025
0.0023
0.30
0.21
0.20
Ref
No.
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
3
3
3
3
3
3
3
4
4
4
4
4
4
4-20
-------
TABLE 4-1. (continued)
Source
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Pollutant
Condensible organic PM
C02
Antimony1
Arsenic
Beryllium
Cadmium
Chromium
Lead
Manganese
Mercury
Nickel
Phosphorus
Selenium
CO
NOX
Total fluorides
Hydrogen fluoride
TOC as propane
Acetone
Acrylonitrilel
Benzene
Bromomethane
2-butanonec
Carbon disulfide
Carbon tetrachloridec
Chloroform0
Chloromethane
Ethylbenzene
2-hexanonec
lodomethane
Methylene chloride
M-/p-xylene
O-xylene1
Styrenec
No. of
test runs
o
3
9
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
9
9
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
Data
rating
A
A
C
A
A
A
A
A
A
A
A
A
A
A
A
NR
A
A
C
C
B
A
C
C
C
C
B
C
C
B
B
C
C
C
Emission factor
range, Ib/ton
0.066-0.11
470-630
3.6xlO-6-1.2xlQ-5
4.5xlO-5-5.5xlQ-5
5.3xlO-7-l.lxlQ-6
6.2xlO-6-2.9xlQ-5
3.3xlO-5-7.1xlO-5
1.7xlO-4-4.8xlQ-4
0.0010-0.036
5.4xlO-6-1.5xlQ-5
2.1xlO-5-4.7xlQ-5
0.0011-0.0018
2.2xlO-5-1.2xlQ-4
2.9-3.5
0.39-0.44
0.0028-0.19
0.21-0.64
0.053-0.060
1.7xlO-4-7.7xlQ-4
9.0xlO-6-2.7xlQ-5
4.0xlO-4-5.8xlQ-4
3.4xlO-5-7.1xlQ-5
NA
1.3xlO-5-2.0xlO-5
NA
NA
1.4xlO-4-0.0010
6.0xlO-6-1.3xlQ-5
NA
1.6xlO-4-2.3xlQ-4
4.1xlO-6-1.0xlQ-5
l.lxlO-5-5.0xlQ-5
1.8xlO-6-5.4xlQ-6
NA
Average emission
factor, Ib/ton
0.081
540
e.SxlO'6
S.lxlO'5
7.2xlO'7
1.7X10'5
S.SxlO'5
S.SxlO'4
0.013
9.9xlO'6
3.4X10'5
0.0014
5.6X10'5
3.2
0.41
0.070
0.46
0.057
3.9xlO'4
l.SxlO'5
5.2xlO'4
S.OxlO'5
BDL (6.6xlQ-6)
1.6X10'5
BDL (S.OxlQ-7)
BDL (S.OxlQ-7)
6.8xlO'4
S.SxlO'6
BDL (S.OxlQ-7)
2.0xlO'4
7.5xlO'6
2.9xlO'5
S.SxlO'6
BDL (4.4xlO'7)
Ref
No.
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4-21
-------
TABLE 4-1. (continued)
Source
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Pollutant
Tetrachloroethanec
Toluene
1,1,1 -trichloroethanec
Trichloroethanec
Trichlorofluoromethane
Vinyl acetate0
Bis(2-ethylhexy)phthalate
Dibenzofuran
DimethylphthalateJ
Di-n-butylphthalate1
2-methylphenolc
Naphthalene1
Phenolh
Filterable PM
Filterable PM- 10
Condensible inorganic PM
Condensible organic PM
CO2
Antimony1
Arsenic
Beryllium
Cadmium
Chromium
Lead
Manganese
Mercury
Nickel
No. of
test runs
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
o
3
o
3
9
3
3
3
3
-\
5
-\
5
-\
5
-\
5
3
Data
rating
C
C
C
C
B
C
B
B
C
C
C
C
B
A
A
A
A
A
C
A
A
A
A
A
A
A
A
Emission factor
range, Ib/ton
NA
6.5xi(r5-i.3xicr4
NA
NA
4.6xlO-6-7.0xlQ-6
NA
1.9xlO-5-3.9xl(r5
1.0xl(T9-3.5xlCr5
1.0xlO-9-3.1xlQ-5
1.0xl(T9-1.8xlO-5
NA
1.0xl(T9-1.0xlCr3
1.0xlO-9-1.9xlQ-4
1.3-1.4
0.22-0.29
0.0037-0.022
0.011-0.088
420-480
2.7xlO-6-3.0xlQ-6
1.7xlO-5-2.5xlQ-5
8.7xlO-8-5.7xlQ-7
1.9xlO-5-2.6xlQ-5
3.0xlO-5-8.1xlQ-5
9.0xlO-6-2.6xlQ-4
3.6xlO-4-5.8xlQ-4
7.2xlO-6-1.7xlQ-5
2.3xlO-5-4.9xlQ-5
Average emission
factor, Ib/ton
BDL (S.OxlQ-7)
l.lxlO'4
BDL (S.OxlQ-7)
BDL (S.OxlQ-7)
5.8xlO'6
BDL (S.OxlQ-7)
2.9xlO'5
l.SxlO'5
l.OxlO'5
e.lxlO'6
BDL (2.0xlQ-9)
3.4xlO'4
7.2X10'5
1.3
0.25
0.013
0.043
460
2.8xlO'6
2.1X10'5
S.lxlO'7
2.2xlO'5
4.8xlO'5
1.2xlO'4
4.8xlO'4
l.lxlO'5
3.4xlO'5
Ref
No.
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4-22
-------
TABLE 4-1. (continued)
Source
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Pollutant
Phosphorus1
Selenium
CO
NOX
Total fluorides
Hydrogen fluoride
TOC as propane
Acetone
Acrylonitrileh
Benzene
Bromomethane
2-butanone
Carbon disulfide
Carbon tetrachloridec
Chloroform0
Chloromethane
Ethylbenzene
2-hexanonec
lodomethane
Methylene chloride
M-/p-xylene
O-xylene
No. of
test runs
o
3
3
9
9
2
o
3
o
3
o
3
o
3
3
3
3
3
o
3
o
3
o
3
o
3
3
3
3
3
-\
^
Data
rating
A
A
A
A
NR
A
A
C
C
B
A
C
C
C
C
B
C
C
A
B
C
C
Emission factor
range, Ib/ton
4.2xlO-4-7.3xlQ-4
3.7xl(T5-5.5xlCr5
2.8-3.2
0.31-0.34
0.010-0.031
0.071-0.32
0.093-0.26
9.3xlQ-4-0.0012
1.5xlO-5-2.6xlQ-5
5.2xlO-4-6.0xlQ-4
3.1xlO-5-5.6xlQ-5
6.7xlO-5-4.4xlQ-4
1.7xlO-5-2.0xlQ-5
NA
NA
0.0013-0.0015
8.2xlO-6-1.2xlQ-5
NA
2.2xlO'4-2.7xlO-4
2.8xlO-5-1.3xlQ-4
1.9xlO-5-4.1xlQ-5
5.6xlO-6-8.8xlQ-6
Average emission
factor, Ib/ton
5.5xlO'4
4.7xlO'5
3.0
0.32
0.020
0.18
0.18
0.0010
1.9xlO'5
5.6xlO'4
4.4xlO'5
2.2xlO'4
l.SxlO'5
BDL(3.8xlQ-7)
BDL(3.8xlQ-7)
0.0014
l.OxlO'5
BDL(3.8xlQ-7)
2.4xlO'4
6.2xlO'5
2.9xlO'5
7.3xlO'6
Ref
No.
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4-23
-------
TABLE 4-1. (continued)
Source
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Coal-fired kilng
Coal-fired kilng
Coal-fired kilng
Coal-fired kilng
Coal-fired kilng
Coal-fired kilng
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Pollutant
Styrenec
Tetrachloroethanec
Toluene
1,1,1 -trichloroethanec
Trichloroethanec
Trichlorofluoromethane
Vinyl acetate0
Bis(2-ethylhexy)phthalateh
Dibenzofuranc
Dimethylphthalatec
Di-n-butylphthalateh
2-methylphenolc
Naphthalene0
Phenolh
Filterable PM
C02
SO2
NOX
Filterable PM
C02
Filterable PM
C02
Filterable PM
C02
Filterable PM
C02
SO2
No. of
test runs
o
3
3
3
3
3
o
3
o
3
o
3
o
3
3
3
3
3
o
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
Data
rating
C
C
C
C
C
B
C
C
C
C
C
C
C
B
B
B
B
B
A
C
A
C
A
C
B
B
B
Emission factor
range, Ib/ton
NA
NA
4.2xl(T4-4.4xlCr4
NA
NA
4.5xlO-6-1.5xl(r5
NA
7.4xlO-5-2.7xl(r4
NA
NA
5.2xl(T6-2.4xlO-5
NA
NA
3.5xlO-5-1.4xlQ-4
0.27-0.36
410-470
0.32-0.37
0.25-0.32
1.9-2.3
400-450
0.58-0.89
130-200
0.50-0.90
140-260
0.25-0.34
180-250
0.31-0.37
Average emission
factor, Ib/ton
BDL (4.2xlO'6)
BDL(3.8xlQ-7)
4.3xlO'4
BDL (5.2xlO'7)
BDL(3.8xlQ-7)
l.OxlO'6
BDL(3.8xlQ-7)
1.4xlO'4
BDL (2.4xlO'9)
BDL (2.4xlO'9)
1.6X10'5
BDL (2.4xlO'9)
BDL (2.4xlO'9)
l.OxlO'4
0.32
440
0.35
0.29
2.1
420
0.76
170
0.73
200
0.28
210
0.35
Ref
No.
4
4
4
4
4
4
4
4
4
4
4
4
4
4
5
5
5
5
6
6
6
6
7
7
8
8
8
4-24
-------
TABLE 4-1. (continued)
Source
Natural gas-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln with
fabric filter
Coal-fired kiln
Brick dryer-waste heat
Brick dryer-waste heat
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Natural gas-fired kiln
with dry scrubber
Natural gas-fired kiln
with dry scrubber
Natural gas-fired kiln
with dry scrubber
Natural gas-fired kiln
with dry scrubber
Brick dryer
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Pollutant
NOX
SO2
CO2
Filterable PM
CO2
Filterable PM
CO2
Filterable PM
CO2
Condensible inorganic PM
Filterable PM
Condensible inorganic PM
Filterable PM
CO2
Filterable PM
Total fluorides
SO2
CO2
S02
Filterable PM
CO2
Filterable PM
Filterable PM
Filterable PM
CO2
Antimony
Arsenic
Beryllium
Cadmium
Chromium
Cobalt
Lead
No. of
test runs
o
3
3
o
3
3
o
3
4
4
3
o
3
3
o
3
3
o
3
3
o
3
o
3
o
3
o
3
3
1
1
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
Data
rating
B
A
C
A
C
A
C
A
C
A
A
A
A
A
A
A
A
C
A
NR
NR
C
NR
A
NR
A
A
C
A
A
C
A
Emission factor
range, Ib/ton
0.24-0.30
1.0-1.3
59-66
0.79-0.90
250-250
0.81-1.0
400-530
0.038-0.051
480-610
0.055-0.16
0.054-0.11
0.11-0.14
1.6-1.7
280-320
0.21-0.26
0.0035-0.0044
0.64-0.66
340-450
0.022-0.027
NA
NA
2.5-3.1
1.6-2.2
0.29-0.44
640-670
0-1.9xlO'4
7.6xlO-6-5.0xlQ-5
2.1xlO-7-2.2xlQ-7
3.3xlO-6-7.1xlQ-6
1.7xlO-5-2.3xlO-5
2.1xlO-6-2.2xlQ-6
1.2xlO-5-2.3xlQ-4
Average emission
factor, Ib/ton
0.27
1.2
62
0.86
250
0.90
470
0.043
550
0.11
0.073
0.13
1.6
300
0.23
0.0040
0.65
370
0.024
3.8
370
2.9
1.9
0.38
650
6.4xlO'5
2.3xlO'5
2.1xlO'7
5.8xlO'6
2.1xlO'5
2.1xlO'6
8.6xlO'5
Ref
No.
8
9
9
10
10
12
12
13
13
15
15
15
15
15
17
17
17
17
17
18
18
19
20
21
21
22
22
22
22
22
22
22
4-25
-------
TABLE 4-1. (continued)
Source
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Unspecified fuel-fired
kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Pollutant
Manganese
Mercury
Nickel
Selenium
Methane
CO
CO2
NOX
SO2
TOC as propane
Filterable PM
Filterable PM
Filterable PM- 10
Condensible inorganic PM
Condensible organic PM
Hydrogen fluoride
Filterable PM
HC1
SO2
S03
Hydrogen fluoride
Total fluorides
HC1
S03
SO2
Hydrogen fluoride
HC1
S02
SO3
Filterable PM
Total fluorides
Hydrogen fluoride
HC1
S02
No. of
test runs
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
-\
^
3
6
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
2
3
-\
5
3
Data
rating
A
C
A
A
C
A
A
A
A
A
A
B
A
A
A
B
B
B
B
B
C
C
C
C
C
B
B
B
B
B
C
D
C
C
Emission factor
range, Ib/ton
7.7xlO-5-9.9xlQ-5
4.9xl(T6-5.3xlO-6
4.4xlO-6-1.9xl(r5
4.0xicr5-4.6xicr5
0.0033-0.0036
0.56-0.59
230-230
0.12-0.13
0.056-0.074
0.068-0.071
0.031-0.039
0.061-0.072
0.045-0.053
0.13-0.20
0.0-0.022
0.81-0.90
0.14-0.19
0.40-0.44
0.99-1.0
0.24-0.34
0.14-0.26
0.35-0.39
0.058-0.12
0.045-0.050
0.22-0.24
0.25-0.30
0.043-0.069
0.52-0.56
0.040-0.063
0.94-1.2
0.23-0.24
0.57-0.69
0.23-0.29
0.60-0.69
Average emission
factor, Ib/ton
S.SxlO'5
S.OxlO'6
l.SxlO'5
4.3X10'5
0.0034
0.58
230
0.13
0.063
0.069
0.035
0.066
0.049
0.17
0.012
0.85
0.17
0.41
0.99
0.28
0.22
0.37
0.097
0.048
0.23
0.28
0.057
0.54
0.051
1.1
0.23
0.63
0.26
0.65
Ref
No.
22
22
22
22
22
22
22
22
22
22
22
22
22
22
22
23m
23m
23m
23m
23m
23n
23n
23n
23n
23n
23p
23?
23p
23?
23p
231
23r
23r
23r
4-26
-------
TABLE 4-1. (continued)
Source
Natural gas-fired kiln
Natural gas-fired kiln
Coal-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
firing structural clay tile
Natural gas-fired kiln
firing structural clay tile
Natural gas-fired kiln
firing structural clay tile
Natural gas-fired kiln
firing structural clay tile
Natural gas-fired kiln
firing structural clay tile
Natural gas-fired kiln
firing structural clay tile
Natural gas-fired kiln
firing structural clay tile
Primary crusher with
fabric filterv
Extrusion line with
fabric filter
Extrusion line with
fabric filter
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural-gas fired kiln
with medium-
efficiency scrubbed
Natural-gas fired kiln
with medium-
efficiency scrubbed
Natural-gas fired kiln
with medium-
efficiency scrubbed
Natural-gas fired kiln
with medium-
efficiency scrubbed
Natural-gas fired kiln
with medium-
efficiency scrubbed
Natural-gas fired kiln
with medium-
efficiency scrubbed
Pollutant
SO3
Total fluorides
Hydrogen fluoride
Hydrogen fluoride
Filterable PM
Total fluorides
S02
C02
Filterable PM
SO2
CO2
PM-10
PM-10W
PM-10W
SO2X
NOX
C02
S02X
NOX
C02
Filterable PM
Condensible organic PM
Condensible inorganic PM
No. of
test runs
o
5
3
-\
5
2
o
3
3
3
3
3
o
5
o
5
o
5
o
5
3
3
o
5
3
o
5
3
3
o
3
-\
5
3
Data
rating
C
C
C
NR
B
B
B
B
B
B
B
D
B
D
A
A
A
A
A
A
A
A
A
Emission factor
range, Ib/ton
0.025-0.056
0.41-0.48
0.18-0.22
0.23-0.24
1.4-2.0
0.62-0.65
7.1-8.2
680-740
0.37-0.40
2.4-3.2
240-290
5.6xlO-4-6.3xlQ-4
0.0025-0.0049
0.0018-0.0039
4.5-6.5
0.21-0.28
470-570
0.86-1.1
0.20-0.25
470-570
0.48-0.92
0.010-0.015
0.014-0.015
Average emission
factor, Ib/ton
0.038
0.44
0.20
0.23
1.7
0.64
7.7
710
0.39
2.9
270
5.9xlO'4
0.0036
0.0027
5.7
0.24
530
1.0
0.23
530
0.70
0.013
0.014
Ref
No.
23r
23s
23'
23U
24
24
24
24
25
25
25
29
29
29
29
29
29
29
29
29
29
29
29
4-27
-------
TABLE 4-1. (continued)
Source
Natural-gas fired kiln
with medium-
efficiency scrubbed
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural-gas fired kiln
with high-efficiency
scrubber2
Natural-gas fired kiln
with high-efficiency
scrubbed
Natural-gas fired kiln
with high-efficiency
scrubbed
Natural-gas fired kiln
with high-efficiency
scrubbed
Natural-gas fired kiln
with high-efficiency
scrubber2
Natural-gas fired kiln
with high-efficiency
scrubber2
Natural-gas fired kiln
with high-efficiency
scrubber2
Natural-gas fired kiln
with high-efficiency
scrubber2
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Natural gas-fired kilnaa
Natural gas-fired kilnaa
Natural gas-fired kilnaa
Natural gas-fired kilnaa
Natural gas-fired kilnaa
Pollutant
Total fluoridesx
S02X
NOX
CO
C02
Filterable PM
Condensible organic PM
Condensible inorganic PM
Total fluorides'5
S02X
NOX
CO
CO2
Filterable PM
Condensible organic PM
Condensible inorganic PM
Total fluoridesx
CO
CO2
Filterable PM
Total fluorides
TOC as propane
SO2
CO2
No. of
test runs
o
3
o
3
3
o
3
3
o
3
3
o
3
3
o
3
3
3
o
3
o
3
3
3
o
3
o
3
o
3
6
6
6
6
6
Data
rating
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
Emission factor
range, Ib/ton
0.16-0.21
1.8-2.0
0.77-0.81
2.7-2.8
320-350
0.10-0.11
0.0034-0.0065
0.0019-0.0034
1.5-2.6
0.0043-0.0061
0.18-0.23
2.3-2.7
430-470
0.11-0.13
0.00074-0.0011
0.00040-0.0019
0.0011-0.0015
1.2-1.3
500-510
0.33-0.76
0.022-0.063
0.00074-0.031
1.2-1.7
300-330
Average emission
factor, Ib/ton
0.18
2.0
0.79
2.7
340
0.11
0.0049
0.0027
2.1
0.0049
0.21
2.4
450
0.12
0.00086
0.0011
0.0013
1.2
510
0.49
0.047
0.011
1.5
310
Ref
No.
29
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
32
32
33
33
33
33
33
4-28
-------
TABLE 4-1. (continued)
Source
Natural gas-fired kilnaa
Natural gas-fired kilnaa
Natural gas-fired kiln
with dry scrubberbb
Natural gas-fired kiln
with dry scrubberbb
Natural gas-fired kiln
with dry scrubberbb
Natural gas-fired kiln
with dry scrubber1*
Natural gas-fired kiln
with dry scrubber
Natural gas-fired kiln
with dry scrubber
Natural gas-fired kiln
with dry scrubber
Natural gas-fired kiln
with dry scrubber00
Natural gas-fired kiln
with dry scrubber00
Natural gas-fired kiln
with dry scrubber00
Natural gas-fired kiln
with dry scrubber00
Natural gas-fired kiln
with dry scrubber00
Natural gas-fired kiln
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Brick dryer (No. 1)
with supplemental gas
burner
Brick dryer (No. 1)
with supplemental gas
burner
Brick dryer (No. 1)
with supplemental gas
burner
Brick dryer (No. 1)
with supplemental gas
burner
Brick dryer (No. 1)
with supplemental gas
burner
Pollutant
NOX
CO
Filterable PM
Condensable inorganic PM
Total fluorides
C02
SO2
SO3
NOX
Filterable PM
Condensable inorganic PM
Total fluorides
C02
NOX
Total fluorides
CO
CO2
Filterable PM
TOC as propane
SO2
C02
CO
No. of
test runs
6
6
-\
5
3
3
6
3
o
5
o
5
o
5
o
5
3
6
3
3
o
5
3
3
-\
^
o
3
3
3
Data
rating
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
NR
NR
A
A
Emission factor
range, Ib/ton
0.20-0.22
0.72-0.86
0.24-0.39
0.017-0.19
0.054-0.058
290-330
0.98-1.0
0.032-0.046
0.24-0.27
0.38-0.44
0.029-0.099
0.044-0.046
290-320
0.32-0.35
0.64-0.74
0.53-0.66
460-480
0.027-0.11
ND-0.034
ND
47-90
0.077-0.20
Average emission
factor, Ib/ton
0.21
0.80
0.32
0.12
0.056
310
1.0
0.037
0.26
0.41
0.072
0.045
310
0.34
0.69
0.59
470
0.070
0.011
ND
70
0.12
Ref
No.
33
33
34
34
34
34
34
34
34
35
35
35
35
35
35
37
37
38
38
38
38
38
4-29
-------
TABLE 4-1. (continued)
Source
Brick dryer (No. 1)
with supplemental gas
burner
Brick dryer (No. 2)
with supplemental gas
burner
Brick dryer (No. 2)
with supplemental gas
burner
Brick dryer (No. 2)
with supplemental gas
burner
Brick dryer (No. 2)
with supplemental gas
burner
Brick dryer (No. 2)
with supplemental gas
burner
Brick dryer (No. 2)
with supplemental gas
burner
Natural gas-fired kilndd
Natural gas-fired kiln
Natural gas-fired kilndd
Natural gas-fired kiln
Natural gas-fired kilndd
Natural gas-fired kiln
Natural gas-fired kiln
Brick dryer (No. 1)
with supplemental gas
burner
Brick dryer (No. 1)
with supplemental gas
burner
Brick dryer (No. 1)
with supplemental gas
burner
Brick dryer (No. 1)
with supplemental gas
burner
Brick dryer (No. 1)
with supplemental gas
burner
Brick dryer (No. 1)
with supplemental gas
burner
Pollutant
NOX
Filterable PM
TOC as propane
S02
CO2
CO
NOX
Filterable PM
TOC as propane
S02
CO2
CO
SO3 (includes dryer SO3
measurements)
NOX
Filterable PM
TOC as propane
SO2
CO2
CO
NOX
No. of
test runs
o
3
o
3
3
3
o
3
o
3
3
3
o
3
3
o
3
3
o
3
o
3
3
3
o
3
-\
5
3
3
Data
rating
NR
A
NR
NR
A
A
NR
A
A
A
A
A
A
A
A
A
NR
A
A
A
Emission factor
range, Ib/ton
ND
0.032-0.045
ND
ND-0.013
60-81
0.039-0.063
ND
0.95-1.8
0.060-0.077
10-11
220-230
0.79-0.89
0.028-0.081
0.077-0.17
0.078-0.20
0.081-0.19
ND
65-80
0.11-0.39
0.054-0.27
Average emission
factor, Ib/ton
ND
0.040
ND
0.0044
67
0.054
ND
1.3
0.067
10
220
0.83
0.049
0.14
0.14
0.14
ND
74
0.27
0.14
Ref
No.
38
38
38
38
-\ o
3s
38
38
38
38
38
38
38
-\ o
3s
38
39
39
39
39
39
39
4-30
-------
TABLE 4-1. (continued)
Source
Brick dryer (No. 2)
with supplemental gas
burner
Brick dryer (No. 2)
with supplemental gas
burner
Brick dryer (No. 2)
with supplemental gas
burner
Brick dryer (No. 2)
with supplemental gas
burner
Brick dryer (No. 2)
with supplemental gas
burner
Brick dryer (No. 2)
with supplemental gas
burner
Natural gas-fired kilnee
Natural gas-fired kilnee
Natural gas-fired kilnee
Natural gas-fired kilnee
Natural gas-fired kilnee
Natural gas-fired kilnee
Natural gas-fired kilnee
Pollutant
Filterable PM
TOC as propane
SO2
C02
CO
NOX
Filterable PM
TOC as propane
SO2
CO2
CO
SO3 (includes dryer SO3
measurements)
NOY
No. of
test runs
o
3
o
3
3
3
o
3
o
3
3
o
3
3
o
3
3
o
3
3
Data
rating
A
A
NR
A
A
A
A
A
A
A
A
A
A
Emission factor
range, Ib/ton
0.025-0.16
0.066-0.11
ND
69-77
0.22-0.31
0.035-0.074
0.41-0.48
0.070-0.085
4.0-4.5
160-170
0.71-0.76
0.20-0.30
0.25-0.28
Average emission
factor, Ib/ton
0.071
0.083
ND
72
0.28
0.056
0.44
0.080
4.3
170
0.73
0.26
0.26
Ref
No.
39
39
39
39
39
39
39
39
39
39
39
39
39
k
m
n
P
q
r
s
t
u
Emission factor units are Ib of pollutant per ton of brick produced, unless noted. To convert from Ib/ton to
kg/Mg, multiply by 0.5. NA = not applicable. NR = not rated. ND = not detected.
Emission factor units are Ib of pollutant per ton of raw material throughput.
BDL = below detection limit. Pollutant was not detected during any test run. Detection limit shown in
parentheses.
Measured simultaneously with Method 26A train.
Measured simultaneously with Method 29 train.
Based on Method 201A sampling train.
Kiln fired by coal and supplemental natural gas.
Emission factor includes data from one nondetect run (emissions estimated as one-half of the detection limit).
Emission factor includes data from two nondetect runs (emissions estimated as one-half of the detection limit).
1.09 percent sulfur in coal
Boral Bricks, Kiln No. 5, Augusta, Georgia. Clay bodies contained sawdust.
Boral Bricks, Phenix City, Alabama.
Boral Bricks, Salisbury, North Carolina. Emissions measured at two kiln stacks and one sawdust dryer stack.
Endicott Brick, Fairbury, Nebraska.
Redlands Brick, East Windsor Hill, Connecticut.
Richtex Brick, Kiln No. 4, Columbia, South Carolina.
Richtex Brick, Kiln No. 2, Columbia, South Carolina.
Richtex Brick, Kiln No. 4, Columbia, South Carolina. Special test to reduce HF emissions. Control method
not documented in Reference 23.
Because of superisokinetic sampling, this emission factor is probably a low estimate of emissions from this
source.
4-31
-------
TABLE 4-1. (continued)
w PM-10 emissions from conveyor drop point and from the addition of fine (325-mesh) manganese dioxide and
barium carbonate powders to the raw material.
x Raw material with high sulfur and fluorine content.
y Medium-efficiency scrubber using a soda-ash/water solution (maintained at pH 7) as the scrubbing media.
This scrubber is designed to reduce SO2 and fluoride emissions, but is not expected to control other pollutants.
z High-efficiency packed-bed scrubber using a soda-ash/water solution as the scrubbing media. This scrubber is
designed to reduce SO2 and fluoride emissions, but is not expected to control other pollutants.
ff Average of data from Kiln 1 and Kiln 2 at Boral Bricks, Smyrna, Georgia.
Same kilns as Reference 35.
00 Same kilns as Reference 34.
Raw material is 17 percent shale and 83 percent fire clay.
ee Raw material is 80 percent shale and 20 percent fire clay.
4-32
-------
TABLE 4-2. EMISSION FACTOR DEVELOPMENT FOR BRICK
AND STRUCTURAL CLAY PRODUCT MANUFACTURING51
Source
Coal-fired kilnb
Coal-fired kiln
Natural gas-fired kiln
Unspecified fuel-fired
kiln
Natural gas-fired kiln
Natural gas-fired kiln
Sawdust-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
firing struct, clay tile
Natural gas-fired kiln
Sawdust-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
with medium-efficiency
scrubber"
Natural gas-fired kiln
with high-efficiency
scrubberp
Natural gas-fired kiln
with dry scrubber
Natural gas-fired kiln
with dry scrubber
Natural gas-fired kiln
Sawdust-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Coal-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Pollutant
Hydrogen fluoride
Hydrogen fluoride
Hydrogen fluoride
(total fluorides - 1 .6)
Hydrogen fluoride
(total fluorides - 1 .6)
Hydrogen fluoride
Hll^M^nom f1l1,n.lM*]»>
Hydrogen fluoride
(total fluorides - 1 .6)
Hydrogen fluoride
Hydrogen fluoride
Hydrogen fluoride
(total fluorides - 1 .6)
Hydrogen fluoride
(total fluorides - 1 .6)
Hydrogen fluoride
Hydrogen fluoride
Hydrogen fluoride
Total fluorides
Total fluorides"1
Total fluorides"1
Total fluorides"1
Total fluorides
Total fluorides
HC1
HC1
HC1
HC1
HC1
Methane/ethane as propane
Methane
Methane
No. of
test
runs
3
3
6
2
3
3
3
3
3
3
3
3
3
3
3
3
3
3
6
3
3
3
3
3
3
3
3
Data
rating
A
C
A
C
C
IN IV
C
B
A
B
A
A
C
B
NA
A
A
A
A
A
A
B
C
C
B
B
C
A
Single facility emission
factor, Ib/ton
0.13
0.20
0.047-1.6 = 0.029
0.23-1.6 = 0.14
0.23
r\ --to
0.44-1.6 = 0.28
0.28
0.30
0.64-1.6 = 0.40
0.69-1.6 = 0.43
0.46
0.63
0.85
1. 6 x candidate HF
factor = 0.59
2.1
0.18
0.0013
0.0040
0.051
0.018
0.057
0.097
0.26
0.41
71%ofTOC
4.9%ofTOC
100%ofTOC
Candidate
emission factor,
Ib/ton (rating)
0.17 (D)
0.37 (C)
a = 0.23
n - 11
range = 0.82
0.59 (E)
2.1 (NR)
0.18 (C)
0.0013 (C)
0.028 (C)
0.17 (D)
a - 0.16
n = 5
range - 0.39
59%ofTOC,
0.037 (E)
Ref
No.
2
23C
33
23J
23d
T>C
23k
23f
1
24
35
4
23S
23h
23d
30
29
30
17
34,35
1
23f
23d
23S
23h
2
22
1
4-33
-------
TABLE 4-2. (continued)
Source
Coal-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Coal-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Sawdust-fired kiln
Coal-fired kilnb
Natural gas-fired kiln
Natural gas-fired kiln
Sawdust-fired kiln
Coal-fired kilnb
Natural gas-fired kiln
Sawdust-fired kiln
Natural gas-fired kiln
Coal-fired kilnb
Natural gas-fired kiln
Natural gas-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Natural gas-fired kiln
Coal-fired kilnb
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Sawdust-fired kiln
Coal-fired kilnb
Natural gas-fired kiln
Natural gas-fired kiln
Sawdust-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Coal-fired kilnb
Pollutant
TOC as propane
TOC as propane
TOC as propane
TOC as propane
TOC as propane
TOC as propane
TOC as propane
Antimony
Antimony
Antimony
Antimonyq
Arsenic
Arsenic
Arsenic
Arsenicr
Beryllium
Beryllium1
Beryllium1
Beryllium
Cadmium
Cadmium
Cadmium
Cadmium
Chromium
Chromium
Chromium
Chromium
Cobalt
Cobalf
Lead
Lead
Lead
Lead
No. of
test
runs
1
6
6
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
Data
rating
A
A
A
B
A
A
A
A
C
A
C
A
A
A
C
A
C
C
A
A
C
A
A
A
A
A
A
C
C
A
C
A
A
Single facility emission
factor, Ib/ton
0.011
0.011
0.074
0.14
0.069
0.074
0.057
1.4xlQ-5
2.2xlO'5
6.4xlO'5
6.3xlO'6
l.SxlO'4
2.3xlO'5
S.lxlO'5
l.SxlO'5
1.6X10'5
2.1xlO'7
3.4xlO'7
7.2xlO'7
IJxlO'5
S.SxlO'5
3.3xlO'6
5.8xlO'6
0.0075
2.1X10'5
S.SxlO'5
7.8xlO'5
0.00011
2.1xlO'6
3.3xlO'4
7.9xlO'5
8.6X10'5
8.6X10'5
Candidate
emission factor,
Ib/ton (rating)
0.062 (C)
a 0.044
n = 7
range - 0.13
2.7xlO'5 (D)
1.3xlQ-4(E)
3.1xlQ-5(D)
1.6xlQ-5(E)
4.2xlO'7 (D)
1.5xlQ-5(D)
0.0075 (NR)
5.1xlQ-5(D)
0.0001 1(NR)
2.1xlQ-6(E)
1.5xlQ-4(D)
Ref
No.
3
33
38,39
2
22
1
4
2
1
22
4
2
22
4
1
2
22
1
4
4
1
2
22
1
22
4
2
1
22
4
1
22
2
4-34
-------
TABLE 4-2. (continued)
Source
Sawdust-fired kiln
Natural gas-fired kiln
Coal-fired kilnb
Natural gas-fired kiln
Natural gas-fired kiln
Coal-fired kilnb
Natural gas-fired kiln
Sawdust-fired kiln
Natural gas-fired kiln
Coal-fired kilnb
Natural gas-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Coal-fired kilnb
Natural gas-fired kiln
Coal-fired kilnb
Natural gas-fired kiln
Sawdust-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Sawdust-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
with dry scrubber
Natural gas-fired kiln
Natural gas-fired kiln
with dry scrubber
Natural gas-fired kiln
Pollutant
Manganese
Manganese
Manganese
Manganese
Mercury
Mercury
Mercuryr
Mercury
Nickel
Nickel
Nickel
Nickel
Phosphorus
Phosphorus
Selenium
Selenium
Selenium
Selenium
SO2
SO2
SO2
SO2
SO2
SO2
SO2
SO2
S02
No. of
test
runs
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
6
Data
rating
A
A
A
A
A
A
C
A
A
A
A
A
A
A
C
A
A
A
A
C
B
B
C
A
B
A
A
Single facility emission
factor, Ib/ton
0.013
0.00073
4.7xlO'5
S.SxlO'5
0.00016
9.6xlO'5
S.OxlO'6
9.9xlO'6
0.0042
l.VxlO'4
l.SxlO'5
3.4xlO'5
0.0014
5.5xlO'4
0.00036
0.00046
4.3xlO'5
5.6xlO'5
0.063
0.23
0.35
0.54
0.65
0.67
0.99
1.0
1.5
Candidate
emission factor,
Ib/ton (rating)
0.013 (E)
2.9xlO'4 (D)
0.00016 (NR)
9.6xlO'5 (E)
7.5xlO'6 (D)
0.0042 (NR)
7.2xlO'5 (D)
9.8xlO'4 (E)
2.3xlO'4 (D)
0.67 (C)
a 0.44
n = 9
range - 1.5
Ref
No.
4
1
2
22
1
2
22
4
1
2
22
4
4
2
1
2
22
4
22
23d
5,8
23f
23S
17
23h
34
33
4-35
-------
TABLE 4-2. (continued)
Source
Natural gas-fired kiln
firing high-sulfur
material
Natural gas-fired kiln
firing structural clay tile
Natural gas-fired kiln
firing high-sulfur
material
Natural gas-fired kiln
firing high-sulfur
material
Natural gas-fired kiln
firing high-sulfur
material
Natural gas-fired kiln
firing structural clay tile
Natural gas-fired kiln
firing high-sulfur
material
Natural-gas fired kiln
with medium-efficiency
scrubber"
Natural-gas fired kiln
with high-efficiency
scrubberp
Natural gas-fired kiln
with dry scrubber
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Sawdust-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Brick dryers with
supplemental gas
burners
Brick dryer with
supplemental gas burner
Brick dryer-waste heat
from coal-fired kiln
Brick dryer-waste heat
from coal-fired kiln
Brick dryers with
supplemental gas
burners
Brick dryer-waste heat
Pollutant
S02m
S02
SO2
S02
SO2m
SO2
SO2
SO2m
SO2m
SO3
SO3
SO3
SO3
SO3
SO3
SO3
CO
CO
Condensible inorganic PM
Filterable PM
Filterable PM
Methane/ethane as propane
No. of
test
runs
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
12
1
3
3
12
3
Data
rating
A
B
A
A
A
B
A
A
A
A
C
C
A
B
A
B
A
B
A
A
A
A
Single facility emission
factor, Ib/ton
2.0
2.9
3.0
4.3
5.7
7.7
10
1.0
0.0049
0.037
0.038
0.048
0.049
0.051
0.26
0.28
0.18
0.44
0.11
0.073
0.080
47%ofTOCs
Candidate
emission factor,
Ib/ton (rating)
5.1 (D)
a = 2.9
n = 7
range 8.0
1.0 (C)
0.0049 (C)
O.ll(D)
a = 0.11
n - 7
range = 0.24
0.31 (E)
O.ll(E)
0.077 (E)
0.043 (E)
Ref
No.
30
25
1
39
29
24
38
29
30
34
23S
23d
38
23f
39
23h
38,39
1
15
15
38,39
2
4-36
-------
TABLE 4-2. (continued)
Source
Brick dryer-waste heat
Brick dryer-waste heat
Brick dryers with
supplemental gas
burners
Brick dryer with
supplemental gas burner
Brick dryers with
supplemental gas
burners
Brick dryers with
supplemental gas
burners
Brick dryers with
supplemental gas
burners
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Pollutant
TOC as propane
TOC as propane
TOC as propane
TOC as propane
CO2
NOX
SO3
1 , 1 -dichloroethane
1,1,1 -trichloroethaner
1 ,4-dichlorobenzene*
2-butanone
2-hexanoner
2-methylnaphthalene
2-methylphenolr
Acetone
Benzene
Benzoic acid
Bis(2-ethylhexy)phthalate
Bromomethane
Butylbenzylphthalate*
Carbon disulfide*
Carbon tetrachlorider
Chlorobenzene
Chloroethane
Chloroform1
Chloromethane*
CO
CO
No. of
test
runs
1
3
6
1
12
6
12
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
1
3
Data
rating
A
A
A
B
A
A
A
C
C
C
C
C
C
C
C
B
B
C
A
C
C
C
B
B
C
B
A
A
Single facility emission
factor, Ib/ton
0.036
0.060
0.11
0.16
71
0.098
0.020
S.OxlO'6
BDL(1.7xlQ-5)
3.2xlO'6
2.5xlO'4
BDL (8.2X10'7)
l.VxlO'6
BDL (2.2X10'6)
6.8xlO'4
2.9xlO'4
2.5xlO'4
4.9xlO'5
2.4xlO'5
1.2X10'6
2.3xlO'6
BDLCl.OxlO'7)
2.1X10'5
l.lxlO'5
BDLCl.OxlO'7)
l.lxlO'4
0.70
0.90
Candidate
emission factor,
Ib/ton (rating)
0.048 (E)
0.14(E)
71 (E)
0.098 (E)
0.020 (NR)
5.0xlQ-6(E)
BDL (E)
3.2xlO'6(E)
2.5xlO'4 (E)
BDL (E)
1.7xlQ-6(E)
BDL (E)
6.8xlO'4 (E)
2.9xlO'4 (E)
2.5xlO'4 (E)
4.9xlO'5 (E)
2.4xlO'5 (E)
1.2xlQ-6(E)
2.3xlO'6 (E)
BDL (E)
2.1xlQ-5(E)
l.lxlQ-5(E)
BDL (E)
l.lxlQ-4(E)
0.80 (D)
Ref
No.
3
2
39
1
38,39
39
38,39
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
o
5
2
4-37
-------
TABLE 4-2. (continued)
Source
Coal-fired kiln
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kiln
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kiln
(^ - ^1 fl W*J IrJIl,
Coal-fired kilnb
Coal-fired kiln
Coal-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
with dry scrubber
Coal-fired kilnb
Coal-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Sawdust-fired kiln
Natural-gas fired kiln
with medium-efficiency
scrubber"
Coal-fired kilnb
Natural gas-fired kiln
Natural gas-fired kiln
Sawdust-fired kiln
Natural gas-fired kiln
Natural-gas fired kiln
with medium-efficiency
scrubber"
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Pollutant
CO2
CO2
CO2
CO2
CO2
CO2
CO2
l_.vJa
CO2
CO2
CO2
Condensible inorganic PM
Condensable inorganic PM
Condensible inorganic PM
Condensible inorganic PM
Condensible inorganic PM
Condensible inorganic PM
Condensible inorganic PM
Condensible inorganic PM
Condensible organic PM
Condensible organic PM
Condensible organic PM
Condensible organic PM
Condensible organic PM
Condensible organic PM
Di-n-butylphthalate
Di-n-octylphthalate*
Dibenzofuranq
Diethylphthalate
Dimethylphthalater
Ethylbenzene
No. of
test
runs
3
3
3
3
9
1
3
t
3
4
3
6
6
3
3
3
3
3
3
3
3
3
3
6
3
3
3
3
3
3
3
Data
rating
C
C
C
C
A
A
A
JSIlv
C
C
C
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
C
C
C
C
B
Single facility emission
factor, Ib/ton
62
170
200
250
270
300
300
3^0
420
470
550
0.0019
0.096
0.12
0.13
0.17
3.1
0.20
0.014
0.048
0.012
0.51
0.081
0.0029
0.013
0
1.2X10'5
3.6xlO'7
1.4X10'6
BDL(7.8xlO'7)
2.1X10'5
Candidate
emission factor,
Ib/ton (rating)
300 (C)
0.48 (D)
O.ll(D)
0(E)
1.2xlQ-5(E)
3.6xlO'7(E)
1.4xlQ-6(E)
BDL (E)
2.1xlQ-5(E)
Ref
No.
9
6
7
10
2
3
15
W
6
12
13
30
34,35
2
15
22
1
4
29
2
22
1
4
30
29
2
2
2
2
2
2
4-38
-------
TABLE 4-2. (continued)
Source
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kiln
Coal-fired kiln
(^ - ^1 fivfA IrJIl,
Coal-fired kilnb
Coal-fired kiln
r1 - ^i f; .*.,•] irjii.
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kiln
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kilnb
Coal-fired kiln with
fabric filter
Extrusion line with
fabric filter™
Fyti'iniifin liiif with
fnVirir filtrrw
Grinding room with
fabric filter5
Grinding room with
fabric filter*
Pollutant
Filterable PM
Filterable PM
Filterable PM
Filterable PM
Filterable PM
Filterable PM
Filterable PM
Filterable PM- 10
Isophorone
M-/p-xylene
Methylene chloride
Naphthalene
NOX
NOX
O-xylene
Phenol
SO2
so/
Styrener
Tetrachloroethaner
Toluene
Trichloroethaner
Trichlorofluoromethane
Vinyl acetater
Filterable PM
PM-10
T^'Pi.T 1 C\
Filterable PM
Filterable PM
No. of
test
runs
6
3
3
3
4
3
6
3
3
3
3
3
1
3
3
3
3
1
3
3
3
3
3
3
3
3
O.
2
3
Data
rating
A
A
A
A
A
IN IV
A
A,C
IN IV
A
B
C
C
A
A
A
B
A
A
A
C
C
C
C
B
C
A
B
14
A
A
Single facility emission
factor, Ib/ton
0.67
0.73
0.76
0.86
0.90
2.1
2.3
63% of fill. PMU
S.OxlO'5
l.SxlO'4
S.OxlO'7
6.9xlO'6
0.30
0.71
4.7xlO'5
3.5xlO'5
1.2
1.2
BDLCl.OxlO'7)
BDLCl.OxlO'7)
2.5xlO'4
BDLCl.OxlO'7)
1.4X10'5
BDLCl.OxlO'7)
0.043
0.0036
c\ nrt'^'7
0.0052
0.0072
Candidate
emission factor,
Ib/ton (rating)
1.2 (A)
0.76 (D)
S.OxlQ-5 (E)
1.3xlQ-4(E)
S.OxlQ-7 (E)
6.9xlQ-6 (E)
0.51 (D)
4.7xlQ-5 (E)
3.5xlQ-5 (E)
1.2(D)
BDL (E)
BDL (E)
2.5xlQ-4 (E)
BDL (E)
1.4xlQ-5(E)
BDL (E)
0.043 (E)
0.0036 (E)
0.0062 (E)
Ref
No.
2
7
6
10
12
6
15,19
2,15
2
2
2
2
3
2
2
2
9
3
2
2
2
2
2
2
13
29
W
1
2
4-39
-------
TABLE 4-2. (continued)
Source
Grinding room with
fabric filter5
Grinding room with
fabric filter*
Grinding room
(14% moisture)x
Grinding room
(3.9% moisture)x
Grinding room
(14% moisture)x
Grinding room
(3.9% moisture)x
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Pollutant
Filterable PM- 10
Filterable PM- 10
Filterable PM
Filterable PM
Filterable PM- 10
Filterable PM- 10
1,1,1-Trichloroethane
1 ,4-dichlorobenzene
2-methylnaphthalene
2-butanone
2-Hexanone
Acetone
Benzene
Bis(2-ethylhexy)phthalate
Butylbenzylphthalate
Carbon disulfide
Chlorine
Chloroethane
Chloromethane
CO
CO
CO
CO
CO
No. of
test
runs
2
3
3
3
3.
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
6
6
3
6
Data
rating
A
A
B
A
JNlv
B
A
B
B
B
C
C
C
B
C
B
B
A
B
B
A
A
A
A
A
Single facility emission
factor, Ib/ton
0.0011
0.0052
0.025
8.5
¥J-
0.0023
0.53
4.7X10'6
4.8xlO'5
5.7xlO'5
0.00022
8.5xlO'5
0.0017
0.0029
0.0020
l.SxlO'5
4.1xlO'5
0.0013
0.00057
0.00067
0.58
0.78
0.80
1.1
2.6
Candidate
emission factor,
Ib/ton (rating)
0.0032 (E)
0.025 (E)
8.5 (E)
0.0023 (E)
0.53 (E)
4.7xlO'6 (E)
4.8X10'5 (E)
5.7X10'5 (E)
0.00022 (E)
S.SxlO'5 (E)
0.0017 (E)
0.0029 (E)
0.0020 (E)
1.8xlQ-5(E)
4.1xlQ-5(E)
0.0013 (E)
0.00057 (E)
0.00067 (E)
1.2(C)
Ref
No.
1
2
4
1
t
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
22
38,39
33
1
30
4-40
-------
TABLE 4-2. (continued)
Source
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
firing structural clay tile
Natural gas-fired kiln
Natural gas-fired kiln
with dry scrubber
Natural gas-fired kiln
Natural gas-fired kilny
Natural gas-fired kiln
with dry scrubber
Natural gas-fired kilny
Natural gas-fired kiln
firing structural clay tile
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
with dry scrubber
Natural gas-fired kiln
Natural gas-fired kiln
with dry scrubber
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kilny
Natural-gas fired kiln
with medium-efficiency
scrubber"
Natural gas-fired kiln
Natural gas-fired kiln
firing structural clay tile
Natural gas-fired kiln
firing structural clay tile
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Pollutant
CO2
CO2
CO2
CO2
CO2
C02
C02
C02
CO2
CO2
CO2
Di-n-butylphthalate
Diethylphthalate
Ethylbenzene
Filterable PM
Filterable PM
Filterable PM
Filterable PM
Filterable PM
Filterable PM
Filterable PM
Filterable PM
Filterable PM
Filterable PM
Filterable PM
Filterable PM
Filterable PM- 10
lodomethane
m-/p-Xylene
No. of
test
runs
6
3
3
6
12
6
6
3
6
3
3
3
3
3
6
6
3
6
6
9
6
6
3
6
3
3
3
3
3
Data
rating
A
A
B
A
A
B
A
C
A
B
A
B
B
B
A3
B
A
B
A
A
A
A
A
A
B
B
A
B
B
Single facility emission
factor, Ib/ton
200
230
270
310
310
330
395
370
530
710
770
0.00014
0.00024
4.4xlO'5
0.051
0.17
0.23
0.30
0.37
0.40
0.49
0.11
0.70
0.88
0.39
1.7
75% of fill. PM
9.3xlO'5
6.7xlO'5
Candidate
emission factor,
Ib/ton (rating)
400 (B)
0.00014 (E)
0.00024 (E)
4.4xlO'5 (E)
0.37 (C)
1.0 (E)
0.28 (E)
/5 % ot tilt. PM
9.3xlO'5 (E)
6.7xlO'5 (E)
Ref
No.
38,39
22
25
33
34,35
5,8
30
17
29
24
1
1
1
1
22
23h
17
5,8
34,35
1
33
30
29
38,39
25
24
22
1
1
4-41
-------
TABLE 4-2. (continued)
Source
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
with dry scrubber
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kilny
Natural gas-fired kilny
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Primary crusher with
fabric filter5'2
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kilnaa
Sawdust-fired kilnaa
Sawdust-fired kilnaa
Pollutant
Naphthalene
NOX
NOX
NOX
NOX
NOX
NOX
NOX
NOX
o-Xylene
Phenol
Styrene
Tetrachloroethene
Toluene
Filterable PM- 10
1,1,1 -trichloroethaner
2-butanoner
2-hexanoner
2-methylphenolr
Acetone
Acrylonitrileq
Benzene
Bis(2-ethylhexy)phthalate
Bromomethane
Carbon disulfide
Carbon tetrachlorider
Chloroform1
Chloromethane
CO
CO
CO
No. of
test
runs
3
3
6
6
6
6
3
6
6
3
3
3
3
3
o.
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
18
Data
rating
C
A
A
A
A
B
A
A
A
B
A
B
A
B
TvTD
-LN-LV
D
C
C
C
C
C
C
B
B
A
C
C
C
B
A
A
A
Single facility emission
factor, Ib/ton
6.5xl(T5
0.13
0.20
0.21
0.30
0.28
0.91
0.24
0.50
5.8xlO'5
8.6xlO'5
2.0xlO'5
2.8xlO'6
0.00016
i i v i o™^
1.1/vlU
5.9xlO'4
BDL (S.OxlO'7)
BDL (6.6X10'6)
BDL (S.OxlO'7)
BDL (2.0xlO'9)
3.9xlO'4
l.SxlO'5
5.2xlO'4
2.9xlO'5
S.OxlO'5
1.6X10'5
BDL (S.OxlO'7)
BDL (S.OxlO'7)
6.8xlO'4
0.59
1.2
3.1
Candidate
emission factor,
Ib/ton (rating)
6.5xlO'5 (E)
0.35 (C)
5.8xlO'5 (E)
8.6xlO'5 (E)
2.0xlO'5 (E)
2.8xlO'6 (E)
0.00016 (E)
5.9xlO'4(E)
BDL (E)
BDL (E)
BDL (E)
BDL (E)
3.9xlO'4(E)
1.5xlQ-5(E)
5.2xlO'4(E)
2.9xlO'5 (E)
S.OxlO'5 (E)
1.6xlQ-5(E)
BDL (E)
BDL (E)
6.8xlO'4 (E)
1.6(D)
Ref
No.
1
22
38,39
33
34,35
5,8
1
29
30
1
1
1
1
1
29
4
4
4
4
4
4
4
4
4
4
4
4
4
37
32
4
4-42
-------
TABLE 4-2. (continued)
Source
Sawdust-fired kilnaa
Sawdust-fired kilnaa
Sawdust-fired kilnaa
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln and
sawdust dryer (parallel)
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kilnaa
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Pollutant
CO2
CO2
CO2
\~s\-S^
Di-n-butylphthalateq
Dibenzofuran*
Dimethylphthalateq
Ethylbenzene
Filterable PM
Filterable PM
Filterable PM
Filterable PM- 10
Filterable PM- 10
lodomethane
M-/p-xylene
Methylene chloride
Naphthaleneq
NOX
O-xyleneq
Phenol1
Styrener
Tetrachloroethaner
Toluene
Trichloroethaner
Trichlorofluoromethane
Vinyl acetater
1,1,1 -trichloroethaner
2-butanone*
2-hexanoner
2-methylphenolr
No. of
test
runs
18
3
3
3
3
3
3
3
3
3
3
2
3
3
3
3
18
3
3
3
3
3
0.
3
3
3
3
3
3
3
Data
rating
A
A
A
IN IV
C
B
C
C
A
A
B
A
B
B
C
B
C
A
C
B
C
C
C
TvTD
-LN-LV
C
B
C
C
C
C
C
Single facility emission
factor, Ib/ton
500
470
510
U J\J
e.ixio'6
l.SxlO'5
l.OxlO'5
8.5xlO'6
0.30
0.38
1.1
70% of fill. PM
84% of fill. PM
2.0xlO'4
2.9xlO'5
7.5xlO'6
3.4xlO'4
0.37
3.8xlO'6
7.2xlO'5
BDL (4.4xlO'7)
BDL (S.OxlO'7)
l.lxlO'4
i~\ /"\^r\
\J . \J i \J
BDL (S.OxlO'7)
5.8xlO'6
BDL (S.OxlO'7)
BDL (5.2xlO'7)
2.2xlO'4
BDL(3.8xlQ-7)
BDL (2.4xlO'9)
Candidate
emission factor,
Ib/ton (rating)
490 (D)
6.1xlQ-6(E)
1.5xlQ-5(E)
1.0xlQ-5(E)
8.5xlO'6 (E)
0.34 (D)
1.1 (NR)
77% of fill. PM
0.26 (D)
2.0xlO'4 (E)
2.9xlO'5 (E)
7.5xlO'6 (E)
3.4xlO'4(E)
0.37 (E)
3.8xlO'6(E)
7.2xlO'5 (E)
BDL (E)
BDL (E)
l.lxlQ-4(E)
BDL (E)
5.8xlO'6(E)
BDL (E)
BDL (E)
2.2xlO'4 (E)
BDL (E)
BDL (E)
Ref
No.
4
37
32
4
4
4
4
4
21
23f
4
14
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4-43
-------
TABLE 4-2. (continued)
Source
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Pollutant
Acetone
Acrylonitrile*
Antimonyq
Arsenic
Benzene
Beryllium*
Bis(2-ethylhexy)phthalatel
Bromomethane*
Cadmium
Carbon disulfide
Carbon tetrachlorider
Chloroform1
Chloromethane
Chromium
Condensible inorganic PM
Condensible organic PM
Di-n-butylphthalate1
Dibenzofuranr
Dimethylphthalater
Ethylbenzene
Filterable PM
Filterable PM- 10
Hydrogen fluoride
No. of
test
runs
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
Data
rating
C
C
C
A
B
A
C
A
A
C
C
C
B
A
A
A
C
C
C
C
A
A
A
Single facility emission
factor, Ib/ton
0.0010
1.9xlO'5
2.8xlO'6
2.1X10'5
5.6xlO'4
S.lxlO'7
1.4xlO'4
4.4xlO'5
2.2xlO'5
l.SxlO'5
BDL(3.8xlQ-7)
BDL(3.8xlQ-7)
0.0014
4.8xlO'5
0.013
0.043
1.6X10'5
BDL (2.4xlO'9)
BDL (2.4xlO'9)
l.OxlO'5
1.3
0.25
0.18
Candidate
emission factor,
Ib/ton (rating)
0.0010 (E)
1.9xlQ-5(E)
2.8xlO'6 (E)
2.1xlQ-5(E)
5.6xlO'4(E)
3.1xlO'7(E)
1.4xlO'4(E)
4.4xlO'5 (E)
2.2xlO'5 (E)
1.8xlQ-5(E)
BDL (E)
BDL (E)
0.0014 (E)
4.8xlO'5 (E)
0.013 (E)
0.043 (E)
1.6xlQ-5(E)
BDL (E)
BDL (E)
1.0xlQ-5(E)
1.3(E)
0.25 (E)
0.18(E)
Ref
No.
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4-44
-------
TABLE 4-2. (continued)
Source
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
° m -IHE+ f; j - -i i-iin an-1
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Pollutant
lodomethane
Lead
M-/p-xylene
Manganese
Mercury
Methylene chloride
Naphthalene1
Nickel
O-xylene
Phenol1
Phosphorusq
Selenium
Styrener
Tetrachloroethaner
TOC as propane
Toluene
T-+n1 f1,,.n,l.;^oe.
Trichloroethaner
Trichlorofluoromethane*
Vinyl acetater
No. of
test
runs
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
2
3
3
3
Data
rating
A
A
C
A
A
B
C
A
C
B
A
A
C
C
A
C
JSIlv
C
B
C
Single facility emission
factor, Ib/ton
2.4xl(T4
1.2xl(T4
2.9xlO'5
4.8xl(T4
l.lxlO'5
6.2xlO'5
BDL (2.4xl(T9)
3.4xl(T5
V.SxlO'6
l.OxlCT4
5.5xl(T4
4.7xl(T5
BDL (4.2xl(T6)
BDL(3.8xl(T7)
0.18
4.3xl(T4
r\ /"i--%/"\
\J.\J2,\J
BDL(3.8xl(T7)
l.OxKT6
BDL(3.8xl(T7)
Candidate
emission factor,
Ib/ton (rating)
2.4xl(T4 (E)
1.2xlQ-4(E)
2.9xl(T5 (E)
4.8xl(T4 (E)
l.lxlQ-5(E)
6.2xl(T5 (E)
BDL (E)
3.4xl(T5 (E)
7.3xl(T6 (E)
1.0xlQ-4(E)
5.5xl(T4(E)
4.7xl(T5 (E)
BDL (E)
BDL (E)
0.18(E)
4.3xl(T4 (E)
BDL (E)
1.0xl(T6(E)
BDL (E)
Ref
No.
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4-45
-------
TABLE 4-2. (continued)
a Emission factor units are Ib of pollutant per ton of brick produced, unless noted. To convert from Ib/ton
to kg/Mg, multiply by 0.5. NA = not applicable. NR = not rated. Data that are crossed out are not used
for emission factor development.
Kiln fired by coal and supplemental natural gas.
0 Richtex Brick, Kiln No. 2, Columbia, South Carolina.
Boral Brick, Phenix City, Alabama.
e Richtex Brick, Kiln No. 4, Columbia, South Carolina. Special test to reduce HF emissions. Method of
reduction not documented in Reference 23.
Boral Brick, Salisbury, North Carolina.
8 Redlands Brick, East Windsor, Connecticut.
Boral Brick, Kiln No. 5, Augusta, GA. Clay bodies contained sawdust.
J Endicott Brick, Fairbury, Nebraska.
Richtex Brick, Kiln No. 4, Columbia, South Carolina.
m Raw material with high sulfur and fluorine content.
n Medium-efficiency scrubber using a soda-ash/water solution (maintained at pH 7) as the scrubbing media.
This scrubber is designed to reduce SO2 and fluoride emissions, but is not expected to control other
pollutants.
p High-efficiency packed-bed scrubber using a soda-ash/water solution as the scrubbing media. This
scrubber is designed to reduce SO2 and fluoride emissions, but is not expected to control other pollutants.
q Emission factor includes data from two nondetect runs (emissions estimated as one-half of the detection
limit).
r Pollutant not detected during all three test runs (detection limit shown in parentheses).
s Methane as a percentage of TOC measured during same test. The candidate emission factor is calculated
by multiplying this percentage by the candidate TOC emission factor for this source.
1 Emission factor includes data from one nondetect run (emissions estimated as one-half of the detection
limit).
11 PM-10 as a percentage of filterable PM measured during same test. The candidate emission factor is
calculated by multiplying this percentage by the candidate filterable PM emission factor for this source.
v 1.09 percent sulfur in coal.
w PM-10 emissions from conveyor drop point and from the addition of fine (325-mesh) manganese dioxide
and barium carbonate powders to the raw material.
x Emission factor units are Ib of pollutant per ton of raw material throughput.
y Includes measurements taken before and after a scrubber that does not control CO, CO2, filterable PM, or
NOX emissions.
z Because of superisokinetic sampling, this emission factor is probably a low estimate of emission from this
source.
aa Includes measurements following a sawdust dryer heated with the exhaust stream from a sawdust-fired
kiln.
4-46
-------
TABLE 4-3. SUMMARY OF EMISSION FACTORS FOR BRICK
AND STRUCTURAL CLAY PRODUCT MANUFACTURING51
Source
Coal-fired kiln
Natural gas- or sawdust-
fired kiln
Natural gas- or sawdust-
fired kiln
Brick kiln with medium-
efficiency scrubber
Brick kiln with high-
efficiency scrubber0
Brick kiln with dry
scrubber
Brick kiln
Brick kiln
Brick kiln
Brick kiln
Coal-fired kiln
Sawdust or natural gas-fired
kiln
Coal-fired kiln
Sawdust or natural gas-fired
kiln
Brick kiln
Brick kiln
Brick kiln
Brick kiln
Sawdust-fired kiln6
Natural gas or coal-fired kiln
Coal-fired kiln
Natural gas- or sawdust-
fired kiln
Brick kiln
Sawdust- or coal-fired kiln
Brick kiln
Natural gas- or sawdust-
fired kiln
Pollutant
Hydrogen fluoride
Hydrogen fluoride
Total fluorides
Total fluorides
Total fluorides
Total fluorides
HC1
Methane
TOC as propane
Antimony
Arsenic
Arsenic
Beryllium
Beryllium
Cadmium
Chromium
Cobalt
Lead
Manganese
Manganese
Mercury
Mercury
Nickel
Phosphorus
Selenium
SO2
No. of
sources
tested
2
11
1
1
1
2
5
3
7
4
1
3
1
3
4
o
3
i
4
1
o
3
i
2
3
2
4
9
Emission
factor
rating
D
C
E
C
C
C
D
E
C
D
E
D
E
D
D
D
E
D
E
D
E
D
D
E
D
C
Emission factor
range, Ib/ton
0.13-0.20
0.029-0.85
1. 6 x candidate HF
factor
NA
NA
0.0040-0.051
0.018-0.41
59% of candidate
TOC factor
0.011-0.14
6.3xlO-6-6.4xlQ-5
NA
1.8xlO-5-5.1xlQ-5
NA
2.1xlO-7-7.2xlQ-7
3.3xlO-6-3.3xlQ-5
2.1xlO-5-7.8xlQ-5
NA
7.9xlO-5-3.3xlQ-4
NA
4.7xlO-5-7.3xlQ-4
NA
5.0xlO-6-9.9xlQ-6
1.3xlO-5-1.7xlO-4
5. 5xlO'4- 0.0014
4.3xlO-5-4.6xlQ-4
0.063-1.5
Candidate
emission
factor, Ib/ton
0.17
0.37
0.59
0.18
0.0013
0.028
0.17
0.037
0.062
2.7xlO'5
l.SxlO'4
S.lxlO'5
1.6X10'5
4.2xlO'7
l.SxlO'5
S.lxlO'5
2.1xlO'6
l.SxlO'4
0.013
2.9xlO'4
9.6xlO'5
7.5xlO'6
7.2xlO'5
9.8xlO'4
2.3xlO'4
0.67
Ref Nos.
2 23
^.^.j
1,4,23,
24,33,35
23
29
30
17,34,35
1,23
1,2,22
1-4,22,
33,38,39
1,2,4,22
2
1,4,22
2
1,4,22
1,2,4,22
2,4,22
22
1,2,4,22
4
1,2,22
2
4,22
2,4,22
2,4
1,2,4,22
5,8,17,
22,23,
33,34
4-47
-------
TABLE 4-3. (continued)
Source
Natural gas-fired kiln firing
high-sulfur material
Natural gas-fired kiln with
medium-efficiency scrubber
Natural gas-fired kiln with
high-efficiency scrubber
Natural gas- or sawdust-
fired kiln
Brick kiln
Brick kiln
Brick dryer with
supplemental gas burner
Brick dryer— waste heat from
coal-fired kiln
Brick dryer
Brick dryer-waste heat
Brick dryer-waste heat
Brick dryer— supplemental
gas burner
Brick dryer with
supplemental gas burner
Brick dryer with
supplemental gas burner
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Pollutant
SO2
S02
SO2
SO3
Condensible inorganic PM
Condensible organic PM
CO
Condensible inorganic PM
Filterable PM
Methane/ethane as propane
TOC as propane
TOC as propane
CO2
NOX
1 , 1 -dichloroethane
1,1,1 -trichloroethane
1 ,4-dichlorobenzene
2-butanone
2-hexanone
2-methylnaphthalene
2-methylphenol
Acetone
Benzene
Benzoic acid
Bis(2-ethylhexy)phthalate
Bromomethane
Butylbenzylphthalate
No. of
sources
tested
7
1
1
7
8
6
2
1
2
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Emission
factor
rating
D
C
C
D
D
D
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
Emission factor
range, Ib/ton
2.0-10
NA
NA
0.037-0.28
0.0019-3.1
0.0029-0.51
0.18-0.44
NA
0.073-0.080
47% of candidate
TOC factor
0.036-0.060
0.11-0.16
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
Candidate
emission
factor, Ib/ton
5.1
1.0
0.0049
0.11
0.48
0.11
0.31
0.11
0.077
0.043
0.048
0.14
71
0.098
S.OxlO'6
BDL1.7xlQ-5
3.2xlO'6
2.5xlO'4
BDL 8.2xlO'7
1.7X10'6
BDL 2.2xlO'6
6.8xlO'4
2.9xlO'4
2.5xlO'4
4.9xlO'5
2.4xlO'5
1.2X10'6
Ref Nos.
1,24,25,
29,30,
38,39
29
30
23,34,
38,39
1,2,4,15,
22,29,30,
34,35
1,2,4,22,
29,30
1,38,39
15
15,38,39
2
2,3
1,39
38,39
39
2
2
2
2
2
2
2
2
2
2
2
2
2
4-48
-------
TABLE 4-3. (continued)
Source
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln
Coal-fired kiln with fabric
filter
Extrusion line with fabric
filter1
Pollutant
Carbon disulfide
Carbon tetrachloride
Chlorobenzene
Chloroethane
Chloroform
Chloromethane
CO
CO2
Di-n-butylphthalate
Di-n-octylphthalate
Dibenzofuran
Diethylphthalate
Dimethylphthalate
Ethylbenzene
Filterable PM
Filterable PM- 10
Isophorone
M-/p-xylene
Methylene chloride
Naphthalene
NOX
O-xylene
Phenol
SO2
Styrene
Tetrachloroethane
Toluene
Trichloroethane
Trichlorofluoromethane
Vinyl acetate
Filterable PM
Filterable PM- 10
No. of
sources
tested
1
1
1
1
1
1
2
10
1
1
1
1
1
1
7
2
1
1
1
1
2
1
1
2
1
1
1
1
1
1
1
1
Emission
factor
rating
E
E
E
E
E
E
D
C
E
E
E
E
E
E
A
D
E
E
E
E
D
E
E
D
E
E
E
E
E
E
E
E
Emission factor
range, Ib/ton
NA
NA
NA
NA
NA
NA
0.70-0.90
62-550
NA
NA
NA
NA
NA
NA
0.67-2.3
0.42-1.4
NA
NA
NA
NA
0.30-0.71
NA
NA
1.2-1.2
NA
NA
NA
NA
NA
NA
NA
NA
Candidate
emission
factor, Ib/ton
2.3xlO'6
BDLl.OxlO'7
2.1X10'5
l.lxlO'5
BDLl.OxlO'7
l.lxlO'4
0.80
300
0
1.2X10'5
3.6xlO'7
1.4X10'6
BDL 7.8xlO'7
2.1X10'5
1.2
0.76
S.OxlO'5
l.SxlO'4
S.OxlO'7
6.9xlO'6
0.51
4.7xlO'5
S.SxlO'5
1.2
BDLl.OxlO'7
BDLl.OxlO'7
2.5xlO-4
BDLl.OxlO'7
1.4xlO'5
BDLl.OxlO'7
0.043
0.0036
Ref Nos.
2
2
2
2
2
2
2,3
2,3,6,7,
9,10,12,
13,15
2
2
2
2
2
2
2,6,7,10,
12,15,19
2,15
2
2
2
2
2,3
2
2
3,9
2
2
2
2
2
2
13
29
4-49
-------
TABLE 4-3. (continued)
Source
Grinding room with fabric
filter8
Grinding room with fabric
filter8
Grinding room
(14% moisture)8
Grinding room
(3.9% moisture)8
Grinding room
(14% moisture)8
Grinding room
(3.9% moisture)8
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln firing
structural clay tile
Pollutant
Filterable PM
Filterable PM- 10
Filterable PM
Filterable PM
Filterable PM- 10
Filterable PM- 10
1,1,1-Trichloroethane
1 ,4-dichlorobenzene
2-methylnaphthalene
2-butanone
2-hexanone
Acetone
Benzene
Bis(2-ethylhexy)phthalate
Butylbenzylphthalate
Carbon disulfide
Chlorine
Chloroethane
Chloromethane
CO
C02
Di-n-butylphthalate
Diethylphthalate
Ethylbenzene
Filterable PM
Filterable PM
No. of
sources
tested
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
5
11
1
1
1
10
2
Emission
factor
rating
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
C
B
E
E
E
C
E
Emission factor
range, Ib/ton
0.0052-0.0072
0.0011-0.0052
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
0.58-2.6
200-770
NA
NA
NA
0.051-0.88
0.39-1.7
Candidate
emission
factor, Ib/ton
0.0062
0.0032
0.025
8.5
0.0023
0.53
4.7xlO'6
4.8xlO'5
5.7xlO'5
0.00022
8.5xlO'5
0.0017
0.0029
0.0020
l.SxlO'5
4.1xlO'5
0.0013
0.00057
0.00067
1.2
400
0.00014
0.00024
4.4xlO'5
0.37
1.0
Ref Nos.
1,2
1 2
1,^
4
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1,22,30,
33,38,39
1,5,8,17,
22,24,25,
29,30,
33-35,38,
39
1
1
1
1,5,8,17,
22,23,29,
30,33-
35,38,39
24,25
4-50
-------
TABLE 4-3. (continued)
Source
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Natural gas-fired kiln
Primary crusher with fabric
filter8
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Pollutant
Filterable PM- 10
lodomethane
m-/p-Xylene
Naphthalene
NOX
o-Xylene
Phenol
Styrene
Tetrachloroethene
Toluene
Filterable PM- 10
1,1,1 -trichloroethane
2-butanone
2-hexanone
2-methylphenol
Acetone
Acrylonitrile
Benzene
Bis(2-ethylhexy)phthalate
Bromomethane
Carbon disulfide
Carbon tetrachloride
Chloroform
Chloromethane
CO
CO2
Di-n-butylphthalate
Dibenzofuran
Dimethylphthalate
Ethylbenzene
Filterable PM
Filterable PM- 10
lodomethane
No. of
sources
tested
1
1
1
1
8
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
o
3
o
3
i
i
i
i
2
2
1
Emission
factor
rating
E
E
E
E
C
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
D
D
E
E
E
E
D
D
E
Emission factor
range, Ib/ton
75% of candidate
fill. PM factor
NA
NA
NA
0.13-0.91
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
0.59-3.1
470-510
NA
NA
NA
NA
0.30-0.38
0.23-0.29
NA
Candidate
emission
factor, Ib/ton
0.28
9.3xlO'5
6.7xlO'5
6.5xlO'5
0.35
S.SxlO'5
8.6X10'5
2.0X10'5
2.8xlO'6
0.00016
5.9xlO'4
BDLS.OxlO'7
BDL 6.6xlO'6
BDLS.OxlO'7
BDL 2.0xlO'9
3.9xlO'4
l.SxlO'5
5.2xlO'4
2.9xlO'5
S.OxlO'5
1.6xlO'5
BDLS.OxlO'7
BDLS.OxlO'7
6.8xlO'4
1.6
490
e.lxlO'6
l.SxlO'5
l.OxlO'5
8.5xlO'6
0.34
0.26
2.0xlO'4
Ref Nos.
22
1
1
1
1,5,8,22,
29,30,33-
35,38,39
1
1
1
1
1
29
4
4
4
4
4
4
4
4
4
4
4
4
4
4,32,37
4,32,37
4
4
4
4
4,21
4,14
4
4-51
-------
TABLE 4-3. (continued)
Source
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Pollutant
M-/p-xylene
Methylene chloride
Naphthalene
NOX
O-xylene
Phenol
Styrene
Tetrachloroethane
Toluene
Trichloroethane
Trichlorofluoromethane
Vinyl acetate
1,1,1 -trichloroethane
2-butanone
2-hexanone
2-methylphenol
Acetone
Acrylonitrile
Antimony
Arsenic
Benzene
Beryllium
Bis(2-ethylhexy)phthalate
Bromomethane
Cadmium
Carbon disulfide
Carbon tetrachloride
No. of
sources
tested
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Emission
factor
rating
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
Emission factor
range, Ib/ton
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
Candidate
emission
factor, Ib/ton
2.9xl(T5
V.SxlCT6
3.4xl(T4
0.37
3.8xl(T6
7.2xl(T5
BDL 4.4xl(T7
BDLS.OxlCT7
l.lxlCT4
BDLS.OxlCT7
5.8xl(T6
BDLS.OxlCT7
BDL 5.2xl(T7
2.2xl(T4
BDL3.8xl(T7
BDL 2.4xl(T9
0.0010
1.9X10'5
2.8xlO'6
2.1xlO'5
5.6xlO'4
S.lxlO'7
1.4xlO'4
4.4xlO'5
2.2xlO'5
LSxlO'5
BDLS.SxlO'7
Ref Nos.
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4-52
-------
TABLE 4-3. (continued)
Source
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Pollutant
Chloroform
Chloromethane
Chromium
Condensible inorganic PM
Condensible organic PM
Di-n-butylphthalate
Dibenzofuran
Dimethylphthalate
Ethylbenzene
Filterable PM
Filterable PM- 10
Hydrogen fluoride
lodomethane
Lead
M-/p-xylene
Manganese
Mercury
Methylene chloride
Naphthalene
Nickel
O-xylene
Phenol
Phosphorus
No. of
sources
tested
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Emission
factor
rating
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
Emission factor
range, Ib/ton
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
Candidate
emission
factor, Ib/ton
BDL3.8xl(T7
0.0014
4.8xlO'5
0.013
0.043
1.6X10'5
BDL 2.4xlO'9
BDL 2.4xlO'9
l.OxlO'5
1.3
0.25
0.18
2.4xlO'4
1.2xlO'4
2.9xlO'5
4.8xlO'4
l.lxlO'5
6.2xlO'5
BDL 2.4xlO'9
3.4X10'5
7.3xlO'6
l.OxlO'4
5.5xlO'4
Ref Nos.
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4-53
-------
TABLE 4-3. (continued)
Source
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Sawdust-fired kiln and
sawdust dryer
Pollutant
Selenium
Styrene
Tetrachloroethane
TOC as propane
Toluene
Trichloroethane
Trichlorofluoromethane
Vinyl acetate
No. of
sources
tested
1
1
1
1
1
1
1
1
Emission
factor
rating
E
E
E
E
E
E
E
E
Emission factor
range, Ib/ton
NA
NA
NA
NA
NA
NA
NA
NA
Candidate
emission
factor, Ib/ton
4.7xl(T5
BDL 4.2xlO'6
BDL3.8xl(T7
0.18
4.3xl(T4
BDL3.8xl(T7
l.OxKT6
BDL3.8xl(T7
Ref Nos.
4
4
4
4
4
4
4
4
a Emission factor units are Ib of pollutant per ton of brick produced, unless noted. To convert from Ib/ton to
kg/Mg, multiply by 0.5. NA = not applicable. NR = not rated. Data that are crossed out are not used for
emission factor development. BDL = below detection limit.
b Medium-efficiency scrubber using a soda-ash/water solution (maintained at pH 7) as the scrubbing media.
This scrubber is designed to reduce SO2 and fluoride emissions, but is not expected to control other
pollutants. This scrubber is not a standard air pollution control device.
c High-efficiency packed-bed scrubber using a soda-ash/water solution as the scrubbing media. This
scrubber is designed to reduce SO2 and fluoride emissions, but is not expected to control other pollutants.
d Dry scrubber using limestone as the sorption medium.
e The facility uses a manganese surface treatment on the bricks. The manganese emission factor for coal-
and natural gas-fired kilns is a better estimate for sawdust-fired kilns firing bricks that do not have a
manganese surface treatment.
r-
PM-10 emissions from conveyor drop point and from the addition of fine (325-mesh) manganese dioxide
and barium carbonate powders to the raw material.
g Emission factor units are Ib of pollutant per ton of raw material throughput.
h Includes measurements following a sawdust dryer heated with the exhaust stream from a sawdust-fired kiln.
4-54
-------
TABLE 4-4. SUMMARY OF PARTICLE SIZE DISTRIBUTION DATA FOR FILTERABLE PM
EMISSIONS FROM KILNS
Source
Sawdust-fired kilna
Sawdust-fired kilna
Sawdust-fired kilnb
Coal-fired kilna
Coal-fired kilnb
Aerodynamic diameter,
microns
10
2.5
1
10
2.5
1
10
10
2.5
1
10
Percent of PM emissions less
than or equal to stated particle
size
73
60
57
84
36
30
67
58
23
9.8
67
Reference No.
4
4
4
14
14
14
4
15
15
15
2
aBased on a particle size distribution test performed using cascade impactors.
bBased on a comparison of PM-10 (measured using EPA Method 201 A) and filterable PM (measured
using EPA Method 5) emissions.
TABLE 4-5. AVERAGE PARTICLE SIZE DISTRIBUTION FOR FILTERABLE PM
EMISSIONS FROM KILNSa
Source
Sawdust-fired kiln
Coal-fired kiln
Aerodynamic diameter,
microns
10b
2.5
1
10b
2.5
1
Percent of PM emissions less
than or equal to stated particle
size
75
48
44
63
23
9.8
Reference No.
4, 14
4, 14
4, 14
2,15
15
15
aParticle size distribution based on cascade impactor tests unless noted.
bBased on cascade impactor particle size distribution and a comparison of PM-10 (measured using
EPA Method 201 A) and filterable PM (measured using EPA Method 5) emissions.
4-55
-------
development. The emission factors are expressed in units of mass of pollutant per mass of brick produced,
unless noted in the text.
4.3.1 Filterable PM
An emission factor for uncontrolled filterable PM emissions from grinding rooms processing
relatively dry (moisture content of about 3.9 percent) raw material was developed using A-rated data from
Reference 1. The emission factor is 4.2 kg/Mg (8.5 Ib/ton) of raw material throughput. This emission factor
is assigned an E rating because it was developed using data from a single test.
An emission factor for uncontrolled filterable PM emissions from grinding rooms processing wet
(moisture content of about 14 percent) raw material was developed using B-rated data from Reference 4. The
emission factor is 0.012 kg/Mg (0.025 Ib/ton) of raw material throughput. This emission factor is assigned
an E rating because it was developed using data from a single test.
An emission factor for fabric filter-controlled filterable PM emissions from grinding rooms was
developed using data from two A-rated tests. Raw material moisture content did not appear to affect the
magnitude of emissions following the control device. The data range from 0.0026 kg/Mg (0.0052 Ib/ton) to
0.0036 kg/Mg (0.0072 Ib/ton) and average 0.0031 kg/Mg (0.0062 Ib/ton). This candidate emission factor is
assigned an E rating because it was developed using data from only two tests.
An emission factor for uncontrolled filterable PM emissions from brick dryers (heated with waste
heat from the cooling section of a coal-fired kiln or from a dryer with supplemental gas burners) was
developed using A-rated data from two tests. The data range from 0.037 kg/Mg (0.073 Ib/ton) to 0.040
kg/Mg (0.080 Ib/ton) and average 0.039 kg/Mg (0.077 Ib/ton) of bricks produced. This emission factor is
assigned an E rating because it was developed using data from only two tests.
An emission factor for uncontrolled filterable PM emissions from coal-fired kilns was developed
using A-rated data from emission tests conducted on seven different kilns and C-rated data from a test
conducted on one of the same kilns. The data range from 0.34 kg/Mg (0.67 Ib/ton) to 1.1 kg/Mg (2.3 Ib/ton)
and average 0.60 kg/Mg (1.2 Ib/ton). This candidate emission factor is assigned an A rating because it was
developed using A-rated data from tests conducted at 7 of about 20 domestic facilities that use coal as the
primary fuel for firing brick kilns.
An emission factor for uncontrolled filterable PM emissions from natural gas-fired kilns was
developed using A- and B-rated test data from tests conducted on 10 kilns. References 5 and 8 document
tests conducted on the same kiln, as do References 34 and 35 and References 38 and 39. The data from these
tests were first averaged and then combined with the average of three filterable PM tests documented in
Reference 1, two tests documented in Reference 22, two tests documented in Reference 30, and single tests
documented in References 17, 23, and 29. The kilns in References 17, 34, and 35 were controlled by dry
scrubbers that did not appear to reduce PM emissions. One of the Reference 30 tests was conducted at the
outlet of a packed bed scrubber that did not control PM emissions. The data range from 0.025 kg/Mg
(0.051 Ib/ton) to 0.44 kg/Mg (0.88 Ib/ton) and average 0.19 kg/Mg (0.37 Ib/ton). This candidate emission
factor is assigned a C rating because it is based on data from 10 of more than 100 facilities that use natural
gas as the primary fuel for firing brick kilns.
An emission factor for uncontrolled filterable PM emissions from sawdust-fired kilns was developed
using A-rated data from two tests. The data range from 0.15 kg/Mg (0.30 Ib/ton) to 0.19 kg/Mg
(0.38 Ib/ton) and average 0.17 kg/Mg (0.34 Ib/ton). This candidate emission factor is assigned a D rating
4-56
-------
because it is based on data from 2 of about 20 facilities that use sawdust as the primary fuel for firing brick
kilns.
An emission factor for uncontrolled filterable PM emissions from a sawdust-fired kiln and sawdust
dryer was developed using A-rated data from a single test. The emission factor is 0.67 kg/Mg (1.3 Ib/ton).
This emission factor is applicable to facilities that vent the kiln exhaust into a rotary drum sawdust dryer,
through cyclones for sawdust recovery, and then to the atmosphere. This emission factor is assigned an E
rating because it is based on data from a single test.
An emission factor for fabric filter-controlled filterable PM emissions from coal-fired kilns was
developed using A-rated data from a single test. The emission factor is 0.022 kg/Mg (0.043 Ib/ton). This
emission factor is assigned an E rating because it is based on data from a single test.
An emission factor for uncontrolled filterable PM emissions from natural gas-fired kilns firing
structural clay tile was developed using B-rated data from two tests. The data range from 0.20 kg/Mg
(0.39 Ib/ton) to 0.85 kg/Mg (1.7 Ib/ton) and average 0.50 kg/Mg (1.0 Ib/ton). This candidate emission factor
is assigned an E rating because it is based on only two tests.
4.3.2 Filterable PM-10
An emission factor for uncontrolled filterable PM-10 emissions from coal-fired kilns was developed
using A-rated data from an EPA Method 201A test and a particle sizing test in conjunction with the filterable
PM emission factor for coal-fired kilns discussed above. The data indicate that about 63 percent of filterable
PM emissions are less than or equal to 10 microns in aerodynamic diameter. Therefore, the average filterable
PM emission factor was multiplied by 0.63 to determine the filterable PM-10 emission factor of 0.38 kg/Mg
(0.76 Ib/ton). This candidate emission factor is assigned a D rating because the PM-10 data represent data
from 2 of about 20 facilities that use coal as the primary fuel for firing brick kilns.
An emission factor for fabric filter-controlled filterable PM-10 emissions from primary crushers was
developed using D-rated data from a single test. The data are D-rated because of superisokinetic sampling,
which should cause the data to underestimate actual emissions, the emission factor is 0.00030 kg/Mg
(0.00059 Ib/ton). This emission factor is assigned an E rating because it is based on D-rated data from a
single test. The magnitude of this factor appears to be reasonable.
An emission factor for uncontrolled filterable PM-10 emissions from grinding rooms processing
relatively dry (moisture content of about 3.9 percent and 16.9 percent silt content) raw material was
developed using A-rated data from Reference 1. The emission factor is 0.27 kg/Mg (0.53 Ib/ton) of raw
material throughput. This emission factor is assigned an E rating because it was developed using data from a
single test.
An emission factor for uncontrolled filterable PM-10 emissions from grinding rooms processing wet
(moisture content of about 14 percent and 4.6 percent silt content) raw material was developed using B-rated
data from Reference 4. The emission factor is 0.0011 kg/Mg (0.0023 Ib/ton) of raw material throughput.
This emission factor is assigned an E rating because it was developed using data from a single test.
An emission factor for fabric filter-controlled filterable PM-10 emissions from grinding rooms was
developed using data from two A-rated tests. Raw material moisture content did not appear to affect the
magnitude of emissions following the control device. The data range from 0.00057 kg/Mg (0.0011 Ib/ton) to
4-57
-------
0.0026 kg/Mg (0.0052 Ib/ton) and average 0.0016 kg/Mg (0.0032 Ib/ton) of raw material throughput. This
candidate emission factor is assigned an E rating because it was developed using data from only two tests.
An emission factor for uncontrolled filterable PM-10 emissions from natural gas-fired kilns was
developed using A-rated filterable PM-10 test data from a single test in conjunction with A- and B-rated
filterable PM test data from twelve tests conducted on seven kilns. Additional PM-10 test data from
Reference 1 indicate that about 33 percent of filterable PM emissions are less than or equal to 10 microns in
aerodynamic diameter. However, this percentage is not consistent with other available PM-10 data for kilns
using different fuels and is not used for emission factor development. The Method 201A test from
Reference 22 indicates that about 75 percent of filterable PM emissions are PM-10 (percentage based on the
PM-10 measurement divided by the sum of the PM-10 measurement and the cyclone catch from the 201A
sampling train). Therefore, the candidate filterable PM emission factor for natural gas-fired kilns was
multiplied by 0.75 to determine the filterable PM-10 emission factor of 0.14 kg/Mg (0.28 Ib/ton). This
candidate emission factor is assigned an E rating because it is based on a single test.
An emission factor for uncontrolled filterable PM-10 emissions from sawdust-fired kilns was
developed from an EPA Method 201A test and a particle sizing test in conjunction with the filterable PM
emission factor for sawdust-fired kilns. The data indicate that about 77 percent of filterable PM emissions
are less than or equal to 10 microns in aerodynamic diameter. Therefore, the average filterable PM emission
factor was multiplied by 0.77 to determine the filterable PM-10 emission factor of 0.13 kg/Mg (0.26 Ib/ton).
This candidate emission factor is assigned a D rating because the PM-10 data represent emissions from 2 of
about 20 facilities that use sawdust as the primary fuel for firing brick kilns.
An emission factor for uncontrolled filterable PM-10 emissions from a sawdust-fired kiln and
sawdust dryer was developed using A-rated data from a single test. The emission factor is 0.13 kg/Mg
(0.25 Ib/ton). This emission factor is applicable to facilities that vent the kiln exhaust into a rotary drum
sawdust dryer, through cyclones for sawdust recovery, and then to the atmosphere. This emission factor is
assigned an E rating because it is based on data from a single test.
An emission factor for fabric filter-controlled filterable PM-10 emissions from an extrusion line was
developed using B-rated data from a single test. The emission factor is 0.0018 kg/Mg (0.0036 Ib/ton). This
factor is not applicable to typical extrusion lines, but is based on data from a line processing very fine
additives and relatively dry raw material. Also, the line includes a conveyor drop point. This emission factor
is assigned an E rating because it is based on data from a single test.
4.3.3 Condensible PM
An emission factor for uncontrolled condensible inorganic PM emissions from brick dryers heated
with waste heat from the cooling section a coal-fired kiln was developed using A-rated data from a single test.
The emission factor is 0.054 kg/Mg (0.11 Ib/ton) of raw material throughput. This emission factor is
assigned an E rating because it was developed using data from a single test.
An emission factor for uncontrolled condensible inorganic PM emissions from coal-, natural gas-,
and sawdust-fired kilns was developed using A-rated data from eight tests. The data for these different fuel
types were combined because the data indicate that, although emissions are highly variable, the fuel type is
not a significant factor in the magnitude of emissions. The data range from 0.00095 kg/Mg (0.0019 Ib/ton)
to 1.6 kg/Mg (3.1 Ib/ton) and average 0.24 kg/Mg (0.48 Ib/ton). This candidate emission factor is assigned a
D rating because the data are highly variable. Emission measurements taken at a scrubber outlet are averaged
with the uncontrolled data because the scrubber is not expected to control condensible PM emissions.
4-58
-------
An emission factor for uncontrolled condensible organic PM emissions from coal-, natural gas-, and
sawdust-fired kilns was developed using A-rated data from six tests. The data for these different fuel types
were combined because the data indicate that, although emissions are highly variable, the fuel type is not a
significant factor in the magnitude of emissions. The data range from 0.0015 kg/Mg (0.0029 Ib/ton) to
0.26 kg/Mg (0.51 Ib/ton) and average 0.055 kg/Mg (0.11 Ib/ton). This candidate emission factor is assigned
a D rating because it is based on data that range over two orders of magnitude. Emission measurements taken
at a scrubber outlet are averaged with the uncontrolled data because the scrubber is not expected to control
condensible PM emissions.
Emission factors for uncontrolled condensible organic and inorganic PM emissions from a sawdust-
fired kiln and sawdust dryer were developed using A-rated data from a single test. The condensible organic
PM emission factor is 0.022 kg/Mg (0.043 Ib/ton), and the condensible inorganic PM emission factor is
0.0064 kg/Mg (0.013 Ib/ton). These emission factors are applicable to facilities that vent the kiln exhaust
into a rotary drum sawdust dryer, through cyclones for sawdust recovery, and then to the atmosphere. These
candidate emission factors are assigned E ratings because they are based on data from a single test.
4.3.4 Total Organic Compounds
An emission factor for uncontrolled TOC (as propane) emissions from brick dryers heated with
waste heat from the kiln cooling zone was developed using A-rated data from two tests. The data range from
0.018 kg/Mg (0.036 Ib/ton) to 0.030 kg/Mg (0.060 Ib/ton) and average 0.024 kg/Mg (0.048 Ib/ton). This
candidate emission factor is assigned an E rating.
An emission factor for uncontrolled TOC (as propane) emissions from brick dryers heated with
waste heat and supplemental gas burners was developed using A- and B-rated data from two tests. The data
range from 0.055 kg/Mg (0.11 Ib/ton) to 0.080 kg/Mg (0.16 Ib/ton) and average 0.068 kg/Mg (0.14 Ib/ton).
This candidate emission factor is assigned an E rating.
An emission factor for uncontrolled TOC (as propane) emissions from brick kilns (including natural
gas-, coal-, and sawdust-fired kilns) was developed using A-rated data from six tests and B-rated data from
one test. The data range from 0.0055 kg/Mg (0.011 Ib/ton) to 0.070 kg/Mg (0.14 Ib/ton) and average
0.031 kg/Mg (0.062 Ib/ton). This emission factor is assigned a C rating.
An emission factor for uncontrolled TOC (as propane) emissions from a sawdust-fired kiln and
sawdust dryer was developed using A-rated data from a single test. The emission factor is 0.090 kg/Mg
(0.18 Ib/ton). This emission factor is applicable to facilities that vent the kiln exhaust into a rotary drum
sawdust dryer, through cyclones for sawdust recovery, and then to the atmosphere. This emission factor is
assigned an E rating because it is based on data from a single test.
4.3.5 Volatile Organic Compounds
The VOC emission factors presented in the revised AP-42 section were calculated by subtracting the
methane and ethane factors from the TOC factors, and then subtracting available factors for other identified
non-reactive compounds (acetone, methylene chloride, trichloroethane, trichlorofluoromethane, and 1,1,1-
trichloroethane).
4-59
-------
4.3.6 Methane and Ethane
An emission factor for uncontrolled methane/ethane emissions from brick dryers was developed
using A-rated data from a single test. The data indicate that 47 percent of TOC emissions are methane/
ethane. Therefore, the candidate TOC emission factor was multiplied by 0.47 to calculate a methane/ ethane
emission factor of 0.022 kg/Mg (0.043 Ib/ton). This emission factor is assigned an E rating because it was
developed using data from a single test.
An emission factor for uncontrolled methane (as propane) emissions from brick kilns (data included
natural gas- and coal-fired kilns) was developed using A-rated data from one test, B-rated data from one test,
and C-rated data from one test. The data range from 4.9 percent of TOC emissions to 100 percent of TOC
emissions (measured during the same test) and average 59 percent of TOC emissions. This percentage is
multiplied by the candidate TOC emission factor for brick kilns to calculate an emission factor 0.019 kg/Mg
(0.037 Ib/ton). This emission factor is assigned an E rating because of the large discrepancy in the
percentages of methane measured during the tests. This emission factor is assumed to apply to all kilns,
although data are not available for methane emissions from sawdust-fired kilns.
4.3.7 Carbon Monoxide
An emission factor for uncontrolled CO emissions from brick dryers heated with waste heat from the
kiln cooling zone and a supplemental natural gas burner was developed using A- and B-rated data from two
tests. The data range from 0.090 kg/Mg (0.18 Ib/ton) to 0.22 kg/Mg (0.44 Ib/ton) and average 0.16 kg/Mg
(0.31 Ib/ton) of dried bricks produced. This emission factor is assigned an E rating because it is based on
data from only two tests.
An emission factor for uncontrolled CO emissions from coal-fired kilns was developed using A-rated
data from two tests. The data range from 0.35 kg/Mg (0.70 Ib/ton) to 0.45 kg/Mg (0.90 Ib/ton) and average
0.40 kg/Mg (0.80 Ib/ton). This candidate emission factor is assigned a D rating because it was developed
using A-rated data from tests conducted at 2 of about 20 domestic facilities that use coal as the primary fuel
for firing brick kilns.
An emission factor for uncontrolled CO emissions from natural gas-fired kilns was developed using
A-rated data from six tests conducted on five kilns. The data range from 0.29 kg/Mg (0.58 Ib/ton) to
1.3 kg/Mg (2.6 Ib/ton) and average 0.60 kg/Mg (1.2 Ib/ton). This emission factor is assigned a C rating
because it is based on data from five of more than 100 facilities that use natural gas as the primary fuel for
firing brick kilns.
An emission factor for uncontrolled CO emissions from sawdust-fired kilns was developed using A-
rated data from four tests conducted on three kilns. Two tests from Reference 4 included a test of the kiln
exhaust and a test conducted following a sawdust dryer that was heated with the kiln exhaust. The sawdust
dryer did not significantly effect CO emissions from the kiln. The data range from 0.30 kg/Mg (0.59 Ib/ton)
to 1.6 kg/Mg (3.1 Ib/ton) and average 0.80 kg/Mg (1.6 Ib/ton). This candidate emission factor is assigned a
D rating.
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4.3.8 Carbon Dioxide
An emission factor for uncontrolled CO2 emissions from brick dryers with supplemental gas burners
was developed using A-rated data from two tests conducted on the same kiln. The candidate emission factor
is 36 kg/Mg (71 Ib/ton). This candidate emission factor is assigned an E rating because it is based on data
from a single kiln.
An emission factor for uncontrolled CO2 emissions from coal-fired kilns was developed using
A-rated data from three tests and C-rated data from seven tests. The data range from 31 kg/Mg (62 Ib/ton) to
230 kg/Mg (550 Ib/ton) and average 150 kg/Mg (300 Ib/ton). This candidate emission factor is assigned a
C rating because C-rated data were used.
An emission factor for uncontrolled CO2 emissions from natural gas-fired kilns was developed using
A-rated data from nine tests conducted on seven kilns, B-rated data from two tests performed on the same
kiln (References 5 and 8), and B- and C-rated data from two tests. The data are first averaged by kiln (data
from References 5 and 8 are averaged, as are the data from References 34 and 35, and the data from
References 38 and 39), and then averaged with the data from the other tests. The data range from 100 kg/Mg
(200 Ib/ton) to 390 kg/Mg (770 Ib/ton) and average 200 kg/Mg (400 Ib/ton). This candidate emission factor
is assigned a B rating because it is based on data from twelve kilns at eleven facilities that use natural gas as
the primary fuel for firing brick kilns.
An emission factor for uncontrolled CO2 emissions from sawdust-fired kilns was developed using A-
rated data from four tests conducted on three kilns. Two tests from Reference 4 included a test of the kiln
exhaust and a test conducted following a sawdust dryer that was heated with the kiln exhaust. The sawdust
dryer did not significantly effect CO2 emissions from the kiln. The data range from 240 kg/Mg (470 Ib/ton)
to 260 kg/Mg (510 Ib/ton) and average 250 kg/Mg (490 Ib/ton). This candidate emission factor is assigned a
D rating.
4.3.9 Nitrogen Oxides
An emission factor for uncontrolled NOX emissions from brick dryers with supplemental gas burners
was developed using A-rated data from a single test. The candidate emission factor is 0.049 kg/Mg
(0.098 Ib/ton). This candidate emission factor is assigned an E rating because it is based on data from a
single test.
An emission factor for uncontrolled NOX emissions from coal-fired kilns was developed using A-
rated data from two tests. The data range from 0.15 kg/Mg (0.30 Ib/ton) to 0.35 kg/Mg (0.71 Ib/ton) and
average 0.25 kg/Mg (0.51 Ib/ton). This candidate emission factor is assigned a D rating because it was
developed using A-rated data from tests conducted at 2 of about 20 domestic facilities that use coal as the
primary fuel for firing brick kilns.
An emission factor for uncontrolled NOX emissions from natural gas-fired kilns was developed using
A- and B-rated data from eleven tests conducted on eight kilns. References 5 and 8 document tests on the
same kiln, as do References 34 and 35, and References 38 and 39. The data are first averaged by kiln, and
then are averaged with the data from the other tests. The data range from 0.065 kg/Mg (0.13 Ib/ton) to
0.45 kg/Mg (0.91 Ib/ton) and average 0.18 kg/Mg (0.35 Ib/ton). This emission factor is assigned a C rating
because it is based on data from 7 of more than 100 facilities that use natural gas as the primary fuel for
firing brick kilns.
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An emission factor for uncontrolled NOX emissions from sawdust-fired kilns was developed using A-
rated data from two tests conducted on the same kiln. One of the tests was conducted following a sawdust
dryer that was heated with the kiln exhaust. The sawdust dryer did not significantly effect NOX emissions
from the kiln. The emission factor is 0.18 kg/Mg (0.37 Ib/ton). This emission factor is assigned an E rating
because it is based on data from a single facility.
4.3.10 Sulfur Dioxide
An emission factor for uncontrolled SO2 emissions from coal-fired kilns was developed using A-
rated data from two tests. The data range from 0.57 kg/Mg (1.2 Ib/ton) to 0.61 kg/Mg (1.2 Ib/ton) and
average 0.59 kg/Mg (1.2 Ib/ton). This candidate emission factor is assigned a D rating because it was
developed using A-rated data from tests conducted at 2 of about 20 domestic facilities that use coal as the
primary fuel for firing brick kilns.
An emission factor for uncontrolled SO2 emissions from sawdust- and natural gas-fired kilns was
developed using A-rated data from four tests, B-rated data from four tests, two of which were performed on
the same kiln (References 5 and 8), and C-rated data from two tests. The data from References 5 and 8 were
averaged first and then averaged with the other data. The data range from 0.032 kg/Mg (0.063 Ib/ton) to
0.75 kg/Mg (1.5 Ib/ton) and average 0.34 kg/Mg (0.67 Ib/ton). This candidate emission factor is assigned a
C rating because it is based on data from 9 of more than 100 facilities that use natural gas as the primary fuel
for firing brick kilns. Several additional tests (References 1, 24, 25, 29, 30, 38, and 39) were not used in
calculating the candidate emission factor because the raw material sulfur content was considerably higher
than is typical, and the test results are not considered representative of typical firing operations.
An emission factor for uncontrolled SO2 emissions from natural gas-fired kilns firing high-sulfur
(one facility documented an average sulfur content of 0.087 percent) material was developed using A-rated
data from five tests and B-rated data from two tests. The data range from 1.0 kg/Mg (2.0 Ib/ton) to
5.0 kg/Mg (10 Ib/ton) and average 2.6 kg/Mg (5.1 Ib/ton). This candidate emission factor is assigned a D
rating because the tests generally did not document the raw material sulfur content.
Emission factors were developed for wet scrubber-controlled SO2 emissions from natural gas-fired
kilns firing high-sulfur material. A factor of 0.50 kg/Mg (1.0 Ib/ton) was developed for a kiln equipped with
a medium-efficiency scrubber using a soda-ash/water solution as the scrubbing media. A factor of
0.0025 kg/Mg (0.0049 Ib/ton) was developed for a kiln equipped with a high-efficiency packed-bed scrubber
using a soda-ash/water solution as the scrubbing liquid. The medium-efficiency scrubber demonstrated a
control efficiency of 82 percent, and the high-efficiency scrubber demonstrated a control efficiency of
99.8 percent. The emission factors are assigned C ratings because, although only single tests were
performed, the units are unique within the industry.
4.3.11 Sulfur Trioxide
An emission factor for uncontrolled SO3 emissions from sawdust- or natural gas-fired kilns was
developed using A-rated data from three tests, B-rated data from two tests, and C-rated data from two tests.
The data range from 0.019 kg/Mg (0.037 Ib/ton) to 0.14 kg/Mg (0.28 Ib/ton) and average 0.055 kg/Mg
(0.11 Ib/ton). This candidate emission factor is assigned a D rating because the data range over almost an
order of magnitude.
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4.3.12 Hydrogen Fluoride
An emission factor was developed for HF emissions from coal-fired kilns using A- and C-rated data
from two tests. The data range from 0.065 kg/Mg (0.13 Ib/ton) to 0.10 kg/Mg (0.20 Ib/ton) and average
0.083 kg/Mg (0.17 Ib/ton). This candidate emission factor is assigned a D rating. Most factors that are
based on only two tests are assigned an E rating, but the rating for this factor was improved one letter grade
because the two kilns represent almost 10 percent of coal-fired brick kilns.
An emission factor for uncontrolled HF emissions from natural gas or sawdust-fired brick kilns was
developed using data from four A-rated, three B-rated, and four C-rated emission tests. These data are
aggregated because, based on the test data, the magnitude of HF emissions from natural gas- and sawdust-
fired kilns is similar. The data range from 0.015 kg/Mg (0.029 Ib/ton) to 0.43 kg/Mg (0.85 Ib/ton) and
average 0.19 kg/Mg (0.37 Ib/ton). Several of the tests actually documented total fluoride emissions, and the
total fluoride results were divided by 1.6 to estimate HF emissions. The "1.6" factor was taken from the only
available test that documented both HF and total fluorides from the same kiln. This candidate emission factor
is assigned a C rating.
An emission factor for uncontrolled HF emissions from a sawdust-fired kiln and sawdust dryer was
developed using A-rated data from a single test. The emission factor is 0.089 kg/Mg (0.18 Ib/ton), and is
presented separately from the other HF data because data from Reference 4 indicate that the sawdust dryer
removes about 60 percent of the HF from the exhaust stream. This emission factor is applicable to facilities
that vent the kiln exhaust into a rotary drum sawdust dryer, through cyclones for sawdust recovery, and then
to the atmosphere. This emission factor is assigned an E rating because it is based on data from a single test.
4.3.13 Total Fluorides
An emission factor for uncontrolled total fluoride emissions from brick kilns was developed using
C-rated data from one test, which indicated that uncontrolled total fluoride emissions are 1.6 times higher
than HF emissions. Therefore, the candidate emission factor for HF was multiplied by 1.6 to develop an
emission factor of 0.30 kg/Mg (0.59 Ib/ton) for total fluorides. This emission factor is assigned an E rating
because it is based on data from a single test.
An emission factor for total fluoride emissions from natural gas-fired kilns controlled with dry
packed bed scrubbers was developed using A-rated data from three tests conducted on two kilns. The data
range from 0.0020 kg/Mg (0.0040 Ib/ton) to 0.025 kg/Mg (0.051 Ib/ton) and average 0.014 kg/Mg
(0.028 Ib/ton). This emission factor is assigned a C rating because it is based on data from most of the dry
scrubbers currently used to control HF emissions from brick kilns.
An emission factor for medium-efficiency wet scrubber-controlled total fluoride emissions from brick
kilns was developed using data from one A-rated test. The scrubber used a soda-ash/water solution
(maintained at pH 7) as the scrubbing media. The emission factor is 0.0090 kg/Mg (0.18 Ib/ton). This
emission factor is assigned a C rating because the source tested is the only domestic brick kiln that uses this
type of scrubber.
An emission factor for high-efficiency wet scrubber-controlled total fluoride emissions from brick
kilns was developed using data from one A-rated test. The packed-bed wet scrubber used a soda-ash/water
solution (maintained at pH 7) as the scrubbing media. The emission factor is 0.00065 kg/Mg
(0.0013 Ib/ton). This emission factor is assigned a C rating because the source tested is the only domestic
brick kiln that uses this type of scrubber.
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4.3.14 Hydrochloric Acid
An emission factor for uncontrolled HC1 emissions from natural gas-fired kilns was developed using
A-rated data from one test, B-rated data from two tests, and C-rated data from two tests. The data range
from 0.0090 kg/Mg (0.018 Ib/ton) to 0.21 kg/Mg (0.41 Ib/ton) and average 0.065 kg/Mg (0.17 Ib/ton). This
emission factor is assigned a D rating because of the wide range of data.
4.3.15 Metals
Emission factors for arsenic, antimony, beryllium, cadmium, chromium, cobalt, lead, mercury,
manganese, nickel, phosphorus, and selenium emissions from brick kilns were developed using data from
four tests. Two of the tests were conducted on natural gas-fired kilns, one test was conducted on a coal-fired
kiln, and one test was conducted on a sawdust-fired kiln. The emissions of each metal measured during the
tests were compared to determine which data should be combined.
Data from all four tests are combined for antimony, cadmium, lead, and selenium because there are
insignificant differences in emissions of these metals from kilns firing the various fuel types. The emission
factors for these pollutants are assigned D ratings.
Data from three tests (representing all three fuel types) are combined for chromium and nickel. The
emission factors for these pollutants are assigned D ratings. The data for chromium and nickel from
Reference 1 are not used for emission factor development because they appear to be high (by a factor of
about 100) due to the atypical raw material used by the facility.
Data from three tests (representing natural gas- and sawdust-fired kilns) are combined for arsenic,
beryllium, and mercury (two tests). The emission factors for these pollutants are assigned D ratings. The
data for arsenic, beryllium, and mercury from coal-fired kilns are presented separately because they are an
order of magnitude or more higher than the data for natural gas- and sawdust-fired kilns. The emission
factors for these pollutants are assigned E ratings because they are based on single tests.
Data from three tests (representing natural gas and coal-fired kilns) are combined for manganese.
The emission factor for this pollutant is assigned a D rating. The manganese data from sawdust-fired kilns
are presented separately because they are about two orders of magnitude higher than the other manganese
data. However, manganese emissions are probably not caused by sawdust combustion, but result from the
use of a brick surface treatment that contains manganese. The emission factor for this pollutant is assigned
an E rating and is footnoted as being representative of operations using manganese surface treatments.
Data for cobalt were only reported for natural gas-fired kilns, and data from one of the two tests are
not used for emission factor development because high background concentrations are reported in the test
report (Reference 1). The emission factor for this pollutant is assigned an E rating. Cobalt emissions are
assumed to result from the raw material; therefore, the cobalt emission factor is assumed to represent
emissions from kilns firing natural gas, coal, or sawdust.
Data from two tests (representing sawdust- and coal-fired kilns) are combined for phosphorus. The
emission factor for this pollutant is assigned an E rating.
Emission factors for arsenic, beryllium, cadmium, chromium, mercury, manganese, nickel, lead,
phosphorus, and selenium emissions from a sawdust-fired kiln and a sawdust dryer were developed from A-
rated data from a single test. No other metals were detected during testing. These emission factors are
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applicable to facilities that vent the kiln exhaust into a rotary drum sawdust dryer, through cyclones for
sawdust recovery, and then to the atmosphere. The emission factors for these metals are assigned an E rating
because they are based on a single test.
4.3.16 Volatile and Semivolatile Organic Compounds
Emission factors for speciated VOC and SVOC were developed for natural gas-, coal-, and sawdust-
fired kilns. In addition, emission factors for VOC and SVOC emissions from a sawdust-fired kiln and
sawdust dryer were developed. These emission factors are all based on single tests and are all assigned E
ratings because they are based on single tests. Factors that are reported as "zero" are based on tests with
mesurements that were lower than the blank measurements.
4.4 SUMMARY OF CHANGES TO AP-42 SECTION
4.4.1 Section Narrative
The section narrative was expanded to include a more complete description of brick and structural
clay product manufacturing processes and was revised to reflect current industry practices. In addition, the
process flow diagram was modified to be consistent with the process description, and Source Classification
Codes (SCC) were added to the figure. The particle size figures were removed from the section. Finally,
comments from industry were addressed prior to finalizing the report. A copy of the comment and response
log is provided in Appendix A.
4.4.2 Emission Factors
The emission factor and particle size distribution tables were completely revised to incorporate the
newly developed emission factors and new particle size data. Also, all of the emission factors that were based
on the AP-42 fuel combustion emission factors were removed from the section. The emission factor ratings
are, for the most part, lower than in the previous section, but are based on more stringent criteria. The
emission factors were developed with higher quality data than the old emission factors.
REFERENCES FOR SECTION 4
1. Emission Testing at a Structural Brick Manufacturing Plant—Final Emission Test Report for Testing
at BeIden Brick Company, Plant 6, Sugarcreek, Ohio, U. S. Environmental Protection Agency,
Research Triangle Park, NC, February 1995.
2. Final Test Report for U. S. EPA Test Program Conducted at General Shale Brick Plant, Johnson City,
TN, U. S. Environmental Protection Agency, Research Triangle Park, NC, December 1993.
3. Flue Gas Characterization Studies Conducted on the 30B Kiln and Dryer Stacks in Atlanta Georgia
for General Shale Corporation, Guardian Systems, Inc., Leeds, AL, March 1993.
4. Final Test Report for U. S. EPA Test Program Conducted at Pine Hall Brick Plant, Madison, NC,
U. S. Environmental Protection Agency, Research Triangle Park, NC, August 1993.
5. Source Emission Test at Belden Brick, Inc., Sugarcreek, Ohio, No. 1 Kiln, Plant 3, CSA Company,
Alliance, OH, March 3, 1992.
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6. Mass Emission Tests Conducted on the Tunnel Kiln No. 6B And No. 28 in Marion, VA, for General
Shale Products Corporation, Guardian Systems, Inc., Leeds, AL, October 1990.
7. Mass Emission Tests Conducted on the Tunnel Kiln No. 21 in Glascow, VA, for General Shale
Products Corporation, Guardian Systems, Inc., Leeds, AL, October 16, 1990.
8. Source Emission Test at Belden Brick, Inc., Sugarcreek, Ohio, No. 1 Kiln, Plant 3, CSA Company,
Alliance, OH, July 21, 1989.
9. Sulfur Dioxide Emission Tests Conducted on the No. 20 Tunnel Kiln in Mooresville, IN, for General
Shale Products Corporation, Guardian Systems, Inc., Leeds, AL, December 2, 1986.
10. Mass Emission Tests Conducted on the No. 7B Tunnel Kiln in Knoxville, TN, For General Shale
Products Corporation, Guardian Systems, Inc., Leeds, AL, April 22, 1986.
11. Exhaust Gas Characterization Studies Conducted on the Plant WBfor General Shale Corporation in
Johnson City, TN, Guardian Systems, Inc., Leeds, AL, February 1984.
12. Mass Emission Tests Conducted on Plant No. 15 in Kingsport, TN, for General Shale Products
Corporation, Guardian Systems, Inc., Leeds, AL, October 11, 1983.
13. Paniculate Emission Tests for General Shale Products Corporation, Kingsport, TN, Tunnel Kiln
TK-29 and Coal Crusher, Guardian Systems, Inc., Leeds, AL, July 21, 1982.
14. 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.
15. Building Brick and Structural Clay Industry, Emission Test Report, Lee Brick and Tile Company,
Sanford, NC, EMB Report 80-BRK-l, U. S. Environmental Protection Agency, Research Triangle Park,
NC, April 1980.
16. Source Sampling Report for Measurement ofP articulate Emissions, Glen-Gery Brick, Bigler Facility
Sawdust Dryer, Gilbert/Commonwealth, Inc., Reading, PA, October 1988.
17. Exhaust Emission Sampling, Acme Brick Company, Sealy, TX, Armstrong Environmental Inc., Dallas,
TX, June 21, 1991.
18. Particulate Compliance Analysis For The Coal-Fired Brick Kiln, The Mogul Corporation, Charlotte,
NC, January 24, 1978.
19. Stationary Source Sampling Report: Lee Brick And Tile Company, Sanford, NC, Compliance Testing,
Tunnel Kiln, Entropy Environmentalists, Inc., Research Triangle Park, NC, February 1978.
20. Stationary Source Sampling Report: Lee Brick And Tile Company, Sanford, NC, Compliance Testing,
Tunnel Kiln, Entropy Environmentalists, Inc., Research Triangle Park, NC, June 1978.
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21. Stationary Source Sampling Report: Chatham Brick And Tile Company, Sanford, NC, Kiln No. 2
Paniculate Emissions Compliance Testing, Entropy Environmentalists, Inc., Research Triangle Park,
NC, July 1979.
22. Stationary Source Sampling Report Reference No. 14448, Triangle Brick, Merry Oaks, North
Carolina, Emissions Testing For: Carbon Monoxide, Condensible Paniculate, Metals, Methane,
Nitrogen Oxides, Paniculate, Paniculate < 10 Microns, Sulfur Dioxide, Total Hydrocarbons,
Entropy, Inc., Research Triangle Park, NC, October, 1995.
23. BIA HF Research Program Stack Testing Results, Center for Engineering Ceramic Manufacturing,
Clemson University, Anderson, SC, November, 1995.
24. Source Emission Tests at Stark Ceramics, Inc., East Canton, Ohio, No. 3 Kiln Stack, CSA Company,
Alliance, OH, September 16, 1993.
25. Crescent Brick Stack Test-No. 2 Tunnel Kiln, CSA Company, Alliance, OH, February 29, 1988.
26. Source Sampling Report, General Shale Products Corporation, Kingsport, TN, P'articulate Emissions
from Beehive Kilns 17 and 15, 9/30/76 and 10/1/76, State of Tennessee Department of Public Health,
Division of Air Pollution Control, 1976.
27. Paniculate Emissions Test, General Shale Products Corporation, Tunnel Kiln 10-B, Johnson City,
Tenn., January 19, 1979, Guardian Systems, Inc., Birmingham, AL, January 19, 1979.
28. General Shale Products Corporation, Tunnel Kiln 10-B, Located in Johnson City, Tennessee,
Paniculate Emissions Test Conducted on December 12, 1978, Guardian Systems, Inc., Birmingham,
AL, December 12, 1978.
29. Emissions Survey Conducted at Interstate Brick Company, Located in West Jordan, Utah, American
Environmental Testing, Inc., Spanish Fork, UT, December 22, 1994.
30. Emissions Survey for SO2, NOX, CO, HF, andPM-10 Emissions Conducted on Interstate Brick
Company's Kiln No. 3 Scrubber, Located in West Jordan, Utah, American Environmental Testing, Inc.,
Spanish Fork, UT, November 30, 1995.
31. Jensen, ].,The Belden Brick Company Plant 6 Grinding Plant EPA Ambient Air Samples, Belden Brick
Company, Sugarcreek, OH, June 7, 1995.
32. Stationary Source Sampling Report for Isenhour Brick Company, Salisbury, North Carolina, No. 6
Kiln Exhausts 1 and 2, Sawdust Dryer Exhaust, Trigon Engineering Consultants, Inc., Charlotte, NC,
October 1995.
33. Paniculate, Fluoride, and CEMEmissions Testing on the #1 and #2 Kiln Exhausts, Boral Bricks, Inc.,
Smyrna, Georgia, Analytical Testing Consultants, Inc., Roswell, GA, September 26, 1996.
34. Source Emissions Survey of Boral Bricks, Inc., Absorber Stack (EPN-K), Henderson, Texas, TACB
Permit 21012, METCO Environmental, Addison, TX, June 1995.
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35. Source Emissions Survey ofBoral Bricks, Inc., Absorber Stack (EPN-K) and Absorber Inlet Duct,
Henderson, Texas, METCO Environmental, Addison, TX, February 1996.
36. Written communication from R. Maner, Boral Bricks, Columbus, GA, to Boral Bricks Environmental
Distribution, September 12, 1996.
37. Stationary Source Sampling Report for Statesville Brick Company, Statesville, NC, Kiln Exhaust,
Sawdust Dryer Exhaust, Trigon Engineering Consultants, Inc., Charlotte, NC, November 1994.
38. Source Emissions Testing, Marseilles Brick, Marseilles, Illinois, Fugro Midwest, Inc., St. Ann, MO,
October 13, 1994.
39. Source Emissions Testing, Marseilles Brick, Marseilles, Illinois, Fugro Midwest, Inc., St. Ann, MO,
July 1, 1994.
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5. PROPOSED AP-42 SECTION
The proposed AP-42, Section 11.3, Brick and Structural Clay Product Manufacturing, is presented on
the following pages as it would appear in the document.
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