### ENCLOSURE 1

**FORM A - GENERA**  **L INFORMA TION**  **Parent Company Information** Parent Company Street Address- Line 1 Street Address- Line 2 City State Zip code Mailing Address (if different)- Line 1 Mailing Address (if different)- Line 2 City State Zip code Number of Employees in Parent Company **(circle one)**  Dun and Bradstreet number **Facility Information**

**Please Number the Facilities**  **Facility ________ Facility ________**  **Facility _________** Facility ID Facility Name Address 1 Address 2 City County State Zip code Mailing Address (if different)- Line 1 Mailing Address (if different)- Line 2 City State Zip code Number of employees at facility **(circle one) 0-99 100-249 250-499 >500**  **0-99 100-249 250-499 >500 0-99 100-249 250-499 >500**  What is your size classification for HAP emissions? **(circle one) Major Source Area Source (Synthetic) Not**  **Sure Major Source Area Source (Synthetic) Not**  **Sure Major Source Area Source (Synthetic) Not**  **Sure** Hours of operation for this facility (hr/yr) Facility's primary NAICS or SIC code Total Number of Periodic Kilns at this Facility Total Number of Tunnel Kilns at this Facility Contact Person for this ICR Contact Phone Number **( ) _____________**

**__________________ ( ) _____________** 

**__________________ ( ) _____________** 

**__________________** Contact Email Address **INFORMA**

**TION COLLECTION REQUEST FOR THE CLA Y CERA** **MICS MA NUFA** **CTURING INDUSTRY**

**0-99 100-249 250-499 >500**

**Please reprint the form to include additional facilities**

**FORM A - Page 1 of 1 INFORMA** 

**TI ON COLLECTION REQUEST FOR THE CLA**  **Y CERA MICS MA** **NUFA CTURING INDUSTRY**  **FORM B - KILN INFORMA TI**  **ON**

Facility ID Kiln ID(s)**(a)** Reporting Ye ar (if not 2007) Type of Kiln **(b)** If periodic, number of identical kilns on this line Ye ar Built Stack Diameter (ft) Does this kiln

have an Air Pollution Control Device (APCD)? **Yes or No** Major Product Types Fired in Kiln Annual

Operating Hours for Kiln Full Design Capacity (tph) Permitted

Capacity (tph) if applicable Average/Actual

Capacity Utilization (%) **(d)**

**Y / N**

**Y / N**

**Y / N**

**Y / N**

**Y / N**

**Y / N**

**Y / N**

**Y / N**

**Y / N**

**Y / N** KILN SIZE **(c)** FACILITY and KILN IDs GENERAL INFORMATION

**(a) Use the ID from your permit or assign using TK-1, 2, etc. for tunnel and RK-1, 2, etc. for roller, and PK-1, 2, etc. for periodic. Use same ID throughout this form. (b) Enter one of these: Tunnel Kiln, Roller Kiln, Shuttle Kiln, Other Periodic Kiln** 

**(d) For sources that have a maximum permitted production capacity higher than the design capacity, enter the actual capacity utilization, which is defined as the actual production divided by the maximum permitted production rate. For sources with an enforceable permit production limit less than the design capacity, enter the average production capacity, which is defined as the actual production divided by the design capacity.**  **(c) Kiln size capacities should be in units of tons per hour (tph) of fired product.**

**FORM B - Page 1 of 2 INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY** 

**FORM B - KILN INFORMATION (Continued)** ADDITIONAL INFORMATION ON PERIODIC KILNS

Facility ID Kiln ID(s)**(a)** Primary Fuel Secondary Fuel Percent Use of Secondary Fuel (% of operating time) Back-up Fuel Reason(s) back-up would be used (e.g., NG curtailment) Total time

back-up fuel was used during year (hr) Kiln

batch capacity (tons) Averag e batch cycle time (hr) Average number of batch cycles per year Average time

required to load unfired shapes into kiln (hr) Average

time required to unload fired shapes from kiln FACILITY and KILN IDs FUEL USAGE



### FORM B - Page 2 of 2**INFORMA TI**  **ON COLLECTION REQUEST FOR THE CLA Y CERA** **MICS MA NUFA** **CTURING INDUSTRY FORM C - GLA** 

**ZE A PPLICA** 

**TI ON INFORMA** 

**TI ON**  GENERAL INFORMATION PLANTWISE GLAZE USE

Facility ID Glaze Line ID(s)**(a)** Number of Spray Booths per Line Reporting

Ye ar (if not 2007) Ye ar Built Annual Operating Hours for Glaze Line Is this glaze line

Controlled with an Air Pollution Control Device (APCD)? **Yes or No** Average

Percentage of HAP's Contained in Glazes **(b)** Glaze Annual

Consumption Annual

Consumption Units (H)*(I)

.... Annual Total of HAPs In Glazes HAPs In Glazes

Units % of HAP Containing

Glazes that are spray applied (if known)

**Y / N**

**Y / N**

**Y / N**

**Y / N**

**Y / N**

**Y / N**

**Y / N**

**Y / N**

**Y / N**

**Y / N** FACILITY and GLAZE LINE IDs

**(b) Enter percentage of spray booth operating time that any glaze, which contains a metal HA P, is applied in the booth. A**  **"HA P containing glaze" is any glaze that contains a material or ingredient listed as a**  **metal HA P on the MSDS for that glaze/material.**  **(a) Use the ID from your permit or assign using GZ-1, 2, etc.**

**FORM C - Page 1 of 1 INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY** 

**FORM D - KILN APCD INFORMATION** APCD Information

Facility ID Kiln ID(s) **(a)** Stack Diameter (ft) Control ID**(b)** Type **(c)** Reason Control was Installed **(d)** Number of kilns vented to this control device Year control

device was installed

**(b) Assign based on ID used in Title V or using CD-1, 2, etc.**

**(d) Select One: Comply with MACT, become Synthetic Minor, SO2 Control, Particulate / Opacity Control, Other. (c) Select One: Dry Limestone Adsorber (DLA), Dry Injection / Fabric Filter (DIFF), Dry Lime Scrubber (DLS), Wet Scrubber, Fabric Filter / Baghouse Only, Lime**  **System (unsure if DIFF or DLS), Spray Dryer / Electrostatic Precipitator, Other. (a) Use the ID from your permit or assign using TK-1, 2, etc. for tunnel and RK-1, 2, etc. for roller, and PK-1, 2, etc. for periodic. Use same ID throughout this form.** 



### FORM D - Page 1 of 4**INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY**

**FORM D - KILN APCD INFORMATION (Continued)**

Facility ID Kiln ID(s) **(a)** Total bag surface area (ft 2 ) Bag- material of

construction Avg. Life

of bags (yrs) Air-to-Cloth Ratio (see instructions) Cleaning method Reagent Type Reagent feedrate (value) Units/ time Total annual reagent usage (indicate units) Is reagent

recirculated or one-pass?**(Enter one)**  If recirculated,

average ratio of recirculated to fresh reagent DIFF or DLS BAGHOUSE/FABRIC FILTER (Stand-alone or as part of DIFF or DLS) FACILITY and KILN IDs

**FORM D - Page 2 of 4 INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY** 

**FORM D - KILN APCD INFORMATION (Continued)** DLA

Facility ID Kiln ID(s) **(a)** Number of cascades Do you use

reconditioning drum/peeler? **Yes or No**  What is the rate at which

limestone is removed from the system as waste? Parameter monitored **(Circle One)** Monitoring frequency

**Y / N Pressure Drop /**  **Alternative**

**Y / N Pressure Drop /**  **Alternative**

**Y / N Pressure Drop /**  **Alternative**

**Y / N Pressure Drop /**  **Alternative**

**Y / N Pressure Drop /**  **Alternative**

**Y / N Pressure Drop /**  **Alternative**

**Y / N Pressure Drop /**  **Alternative**

**Y / N Pressure Drop /**  **Alternative**

**Y / N Pressure Drop /**  **Alternative**

**Y / N Pressure Drop /**  **Alternative** FACILITY and KILN IDs



### FORM D - Page 3 of 4**INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY FORM D - KILN APCD INFORMATION (Continued)** 
WET SCRUBBER OTHER CONTROL (please identify parameters and units monitored to verify control is functioning properly)

Facility ID Kiln ID(s) **(a)** Type of scrubber (e.g., venturi) Liquid

flow rate (gpm) Pressure drop

across scrubber (inches of water) pH range of

scrubbing liquid Reagents used to

maintain pH in desired range Total annual

reagent usage Units /

Time Design or Monitoring Parameter Units /

Time Design or

Monitoring Parameter Units /

Time Design or Monitoring Parameter Units /

Time FACILITY and KILN IDs



### FORM D - Page 4 of 4

### INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY

**FORM E - GLAZE LINE APCD INFORMATION** FACILITY and GLAZE LINE IDs CONTROL DEVICE INFORMATION

Facility ID Glaze Line ID(s)

**(a)** Control ID **(b)** Ty pe**(c)** Reason Control was Installed Number of spray booths vented to this control device Year

control device was installed

**(a) Use the ID from your permit or assign using GZ-1, 2, etc.**

**(c) Enter One: Water Curtain, Wet Scrubber, Fabric Filter, Other. (b) Assign based on ID used in Title V or using CD-1, 2, etc.** 



### FORM E - Page 1 of 3

### FORM E - Page 1 of 3**INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY**

**FORM E - GLAZE LINE APCD INFORMATION (Continued)**
FACILITY and GLAZE LINE IDs BAGHOUSE/FABRIC FILTER WE T SCRUBBER

Facility ID Glaze Line ID(s)

**(a)** Total bag

surface area (ft 2 ) Bag - material of

construction Avg. Life of bags (yrs) Cleaning method Type of scrubber (e.g., venturi) Liquid flow rate (gpm) Pressure drop

across scrubber (inches of water)

**(a) Use the ID from your permit or assign using GZ-1, 2, etc.**



### FORM E - Page 2 of 3**INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY**

**FORM E - GLAZE LINE APCD INFORMATION (Continued)**
FACILITY and GLAZE LINE IDs WATER CURTAIN OTHER CONTROL (please identify parameters and units monitored to verify control is functioning properly)
Facility ID Glaze Line ID(s)

**(a)** Wa ter flow

rate (gpm) Wi dth of water

curtain (ft) Equipped with baffle or

mist eliminator? **(b)** Design or Monitoring Parameter Units / Time Design or Monitoring Parameter Units / Time Design or Monitoring Parameter Units / Time

**(b) Enter One: Baffles, Mist Eliminator, Both, or Neither. (a) Use the ID from your permit or assign using GZ-1, 2, etc.** 



### FORM E - Page 3 of 3**INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY FORM F - TEST DATA** 
GENERAL INFORMATION TEST INFORMATION

FAC ID Control ID Kiln/Glaze Line/Stack ID Test Date Report Date Type of Test - **Circle One** HF HCl PM HAP Metals Other (list below) Other (list below) Other (list below) Uncontrolled (or inlet to control) Controlled Both Uncontrolled (or inlet to control) Controlled Both Uncontrolled (or inlet to control) Controlled Both Uncontrolled (or inlet to control) Controlled Both Uncontrolled (or inlet to control) Controlled Both Uncontrolled (or inlet to control) Controlled Both Uncontrolled (or inlet to control) Controlled Both Uncontrolled (or inlet to control) Controlled Both Uncontrolled (or inlet to control) Controlled Both Uncontrolled (or inlet to control) Controlled Both POLLUTANTS TESTED (Please put **X**in box to indicate pollutant was tested)

**Note** : Please provide copies of full test reports to minimize the need for future information requests. Field notes and raw reading sections can be omitted. However, please include all other sections of the reports, including sample calculations, laboratory data, run-by-run emission data, and a description of any deviations from test methods or other anomalies that occurred with the process or control device operations during the test. Please also provide information on the following for each test: production rate in units of fired product (tph); APCD parameters monitored and monitored values; and any anecdotal information you believe would potentially be helpful to us.



### FORM F - Page 1 of 2**INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY**

**FORM F - TEST DATA (Continued)**
GENERAL INFORMATION

FAC ID Control ID Kiln/Glaze

Line/ Stack ID Reasons for Test APCD Parameters Monitored During Test Notes ADDITIONAL INFORMATION



### FORM F - Page 2 of 2**INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY**

**FORM G - MONITORING AND OTHER COSTS Facility ID**  **Unit Costs for January 2008**

Parameter Cost Electricity cost, $/kwh Reagent: Reagent Cost, $/ton Wa ste Reagent disposal cost, $/ton or $/yr Wa ter treatment costs, $/gal

Activity Required by Activity Estimated Hours Frequency Staff Level -**Select One** Operator, Maintenance, Engineer, Manager Develop a start-up, shutdown, and malfunction plan Develop plan and educate staff Develop and implement an operating, maintenance, and monitoring plan Develop plan and educate staff Bag replacement Replace single bag Bag replacement Replace all bags Maintain free-flowing lime (Describe action in next box and then add estimated hours, frequency, and staff level) Meet requirement to "maintain adequate amount of limestone in hopper." (Describe action taken in next box, then add estimated hours, frequency, and staff level). If different approaches are taken at different plants, please add rows and provide information on each approach

Control Device: Compliance demonstration Activity (describe and estimate hours, frequency, and staff level)
Compliance demonstration Activity (describe and estimate hours, frequency, and staff level) **Standard Activities- DLA (limestone) Standard Activities- Baghouse/DIFF/DLS** 

**Standard Activities- Wet Scrubber or Other Control**



### FORM G - Page 1 of 2Activity Required by Activity Estimated Hours Frequency Staff Level -**Select One** Operator, Maintenance, Engineer, Manager
Compliance demonstration Activity (describe and estimate hours, frequency, and staff level)



### FORM G - Page 1 of 2**INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY**

**FORM G - MONITORING AND OTHER COSTS (Continued) Facility ID** 

Activity Required by Activity Estimated Hours Frequency Staff Level -**Select One** Operator, Maintenance, Engineer,

Manager
Daily Maintenance (list activity(ies) in next column)
We ekly Maintenance (list activity(ies) in next column) Monthly Maintenance (list activity(ies) in next column) Semi-Annual Maintenance (list activity(ies) in next column) Yearly Maintenance (list activity(ies) in next column) Other Frequency Maintenance (specify frequency and list activity(ies) in next column)

**Stack Test Costs for the Previous 3 Years**

Stack Test Year Test Methods (please list all test methods conducted during stack test) **Uncontrolled** (include uncontrolled stack or APCD inlet)? **Controlled? Both? Select**  **One** Cost ($) Notes (Include Any site/preparation costs not included in estimate)

Please also provide separately an itemized list of site/preparation costs not included in the estimate (e.g., costs for drilling ports in stack, costs for installing permanent access to sampling ports, etc.) **Standard Activities- All Controls**

**FORM G - Page 2 of 2 INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY** 

**FORM H - ECONOMICS IMPACT INFORMATION**

Facility ID Product type Average Selling Price per Ton ($) Reporting Year for

Selling Price (if not 2007) Operator wage

rate, $/hr Maintenance wage

rate, $/hr Engineer wage

rate, $/hr Managerial/Supervisory

wage rate, $/hr Product Selling Price Labor Rates as of January 2008



### FORM H - Page 1 of 1**Response**



## 1. Please provide a copy of the cost estimate for your selected control device and explain any differences between the estimated and final installed costs. Costs should include costs for ancillary equipment, such as reconditioning drums, water treatment systems, etc



## 2. Do you currently do any work or operating practices (i.e., other than the use of an air pollution control device) that would have an impact on HF, HCl, or PM emissions from your kilns? If yes, please explain.



## 3. If you operate periodic kilns, please provide a time-temperature profile for each typical batch cycle. The profiles should show the duration of each temperature phase of the cycle from the time the kiln is fired to the time when the fired shapes can be removed from the kiln. (See instructions for example profile.)



## 4. If you operate periodic kilns, do you have any information regarding technological and/or economic limitations to testing those kilns?



## 5. Please provide a copy of a process flow diagram for your facility, if available. **Question INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY**  **FORM I - ADDITIONAL QUESTIONS**



### FORM I - Page 1 of 1