Enclosure 3 

Information Collection Request for Clay Ceramics Manufacturing 

Instructions 

 For hard copy submittals, please return the completed information collection request 

(ICR) by August 13, 2008 to: 

 Mr. Jeffrey Telander 

 Sector Policies and Programs Division (D243-02) 

 U. S. Environmental Protection Agency 

 Office of Air Quality Planning and Standards 

 Research Triangle Park, North Carolina 27711 

 If you wish to complete the ICR electronically, you can return the ICR file on compact 

disc (CD) or diskette to Mr. Telander at the address above. You can also email your submittal to 

Mr. Telander at: telander.jeff@epa.gov. If you email the ICR to Mr. Telander, please send the 

other requested documents (e.g., emission test reports) to Mr. Telander at the above address. 

 If you need clarification of any question or requested information, you can contact 

Mr. Telander at (919) 541-5427. 

 This information request should be completed for each facility that manufactures clay 

ceramics, including facilities that are major sources of hazardous air pollutants (HAP) and 

facilities that are synthetic minor sources of HAP. In addition to general information about your 

company and facilities, information is requested for all kilns at each plant, the emission controls 

associated with kilns, emission data, and other information related to monitoring emissions and 

complying with applicable emission standards. 

 If you believe that any of the specific information requested is proprietary or confidential, 

hereafter referred to as confidential business information (CBI), you should clearly highlight or 

label the specific information. Please do not label the entire ICR, or an entire page of the ICR, as 

“confidential” if only certain portions consist of CBI. Also, do not submit information that you 

consider to be CBI through e-mail. 

 If you are completing the electronic version of the ICR, highlight in red each cell that 

contains CBI. To highlight a cell or cells in Excel in red, first select the cell(s) to be highlighted, 

then on the Format menu, click on “Cells...,” then click on “Pattern,” then under “Cell Shading” 

and “Color,” click on the small red colored box. If you are completing the hard copy version of 

the ICR, either highlight or label any information that you consider CBI (e.g., by circling the data 

and writing “CBI” adjacent to the data). 

 This ICR has been designed in the form of an Excel spreadsheet. We would appreciate 

your completing the survey electronically. However, you may also fill in the attached paper copy 

of the ICR. 
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 The ICR consists of nine different worksheets: 

Form A - General Information. This worksheet requests information on your overall 

parent company and on each facility that manufactures clay ceramic products. 

 Form B - Kiln Information. This worksheet requests information on each kiln at each 

facility, including kilns that currently are not in operation (i.e., inactive kilns). 

Form C - Glaze Line Information. This worksheet requests information on glaze lines 

at each facility. 

Form D - Kiln APCD Information. This worksheet addresses air pollution control 

devices (APCDs) that are used to control emissions from any kiln. 

Form E - Glaze Line APCD Information. This worksheet asks for information on 

APCDs that are used to control emissions from glaze lines. 

Form F - Test Data. This worksheet asks for information on emission tests performed on 

kilns and glaze lines at your facilities. Please note that complete copies of emission test reports 

are requested. 

Form G - Monitoring and Other Costs. This worksheet requests information about the 

costs for monitoring and the operation and maintenance (O&M) activities associated with 

APCDs. Emission test cost data also are requested on this worksheet. 

Form H - Economic Impacts Information. This worksheet requests information on 

product selling price and labor rates. 

Form I - Additional Questions. This worksheet requests information on control device 

costs, raw materials, work practices, periodic kiln operation, and overall process operations at 

each facility. 

 If needed to provide the requested information on each of your facilities, kilns, glaze 

lines, or control devices, please insert columns or rows on the worksheets. For the hard copy 

version, please copy pages as needed to provide all of the requested information. Note also that 

Forms B, D, E, F, and G in the spreadsheet version do not fit on one screen, and you must either 

scroll to the right (Forms B, D, E, and F) or down (Form G) to see the entire worksheet. In the 

hard copy version, these forms are two or more pages long, as follows: Form B -- 2 pages; Form 

D -- 4 pages, Form E -- 3 pages, Form F -- 2 pages, and Form G -- 2 pages. 

 Many of the worksheets include cells that are shaded yellow. Each of these cells has a 

pull-down menu for responses. Click on the box, then on the arrow on the right hand side of 

box, and select a response from the list. For the unshaded cells, the information should be keyed 

in. There is no need to change the column widths if your response does not fit within the cell. In 

the hard copy version of the ICR, suggested responses are listed in the footnotes to each form. 
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 Several worksheets request data on annual production, consumption, sales, or hours for 

various activities. Please provide the totals for 2007 or the most recent year for which you have 

the requested data. If you provide annual data for a year other than 2007, please indicate the year 

in the appropriate cells. 

 A list of abbreviations used in the ICR is attached. 

 The following paragraphs provide more details on how to complete the requested 

information on each of the worksheets. 

 FORM A -- GENERAL INFORMATION 

 The information at the top of this worksheet (Rows 5 through 17) pertains to your overall 

parent company. Please fill this information in the first column. The remaining rows, beginning 

with Row 22 apply to individual facilities. Please fill in a column for each facility. Please assign 

a Facility identification (ID) number consisting of the first four letters in the parent company 

name, followed by a number (e.g., ABCD-1, ABCD-2, etc.). These same Facility IDs must be 

used throughout the ICR where requested on other worksheets. We will assume that all plants 

with the same street address are within one “source” for major source determination, unless you 

note otherwise. 

 FORM B -- KILN INFORMATION 

 Please provide the requested information for each kiln at each facility, including any kilns 

that are not currently in operation (i.e., inactive kilns). Enter the Facility ID assigned on Form A, 

then enter either the ID from your permit, or use TK-1, TK-2, etc., for tunnel kilns; RK-1, RK-2, 

etc., for roller kilns; and PK-1, PK-2, etc., for periodic kilns. Use a separate row for each tunnel 

or roller kiln. However, if a facility has several identical periodic kilns, you can use one row to 

represent all of the identical periodic kilns. In such a case, the kiln IDs should be assigned to 

indicate the number of periodic kilns (e.g., PK-1 to PK-12). For kilns that are not currently in 

operation, please provide the requested information based on the most recent operating data you 

have and select “Tunnel-inactive” under “Type of Kiln” in Column D. 

 Enter the reporting year (if not 2007). For stack diameter, enter the diameter of the kiln 

stack if it is uncontrolled, or the diameter at the outlet of the APCD if the kiln is controlled. List 

each major product type fired in the kiln if the manufacturing of that product impacts processing 

or production rate. There is no need to differentiate between products that are identical other 

than size (e.g., tiles of different dimensions). For sources that have a maximum permitted 

production capacity that is 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 that is less than the design capacity, 

enter the average production capacity, which is defined as the actual production divided by the 

design capacity. 
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 FORM C -- GLAZE LINE INFORMATION 

 For each glaze line, enter the Facility ID assigned on Form A, then enter the glaze line ID 

from your permit, or assign an ID using GZ-1, GZ-2, etc. Enter the reporting year, if different 

from 2007, and the other information requested, including the number of spray booths per glaze 

line. Enter the average percentage of HAPs contained in glazes and the glaze annual 

consumption, and calculate the annual total of HAPs in glazes. Also enter the percentage of HAP 

containing glazes that are spray applied, if known. A “HAP containing glaze” is any glaze that 

contains a material or ingredient listed as a metal HAP on the Material Safety Data Sheet 

(MSDS) for that glaze/material. 

 FORM D -- KILN APCD INFORMATION 

 Please enter the requested information in each row for each APCD that controls 

emissions from any of your kilns. Enter the same Facility ID and kiln ID numbers that you 

entered on Forms A and B. For each control device, enter the ID from your permit, or CD-1, 

CD-2, etc. For baghouses or fabric filters, the air-to-cloth ratio is determined as the design 

exhaust flow (actual cubic feet per minute [acfm]) divided by the total surface area of the bags 

(square feet [ft2

]). For control devices other than those listed in the worksheet, please specify up 

to three design or monitoring parameters for each and indicate the units for each parameter. 

 FORM E -- GLAZE LINE APCD INFORMATION 

 Please enter the requested information in each row for each APCD that controls 

emissions from any of your glaze lines. Enter the same Facility ID and glaze line ID numbers 

that you entered on Forms A and D. For each control device, enter the ID from your permit, or 

CD-1, CD-2, etc. 

 FORM F -- TEST DATA 

 Please complete the summary information requested in this worksheet and also provide a 

copy of each complete test report. For each test, enter the same Facility ID, kiln ID, glaze line 

ID, and Control ID numbers that you entered on previous worksheets. 

 

 When submitting the test reports, field notes and raw reading sections can be omitted. 

However, you must submit 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 records for the following for each test: type of product fired, production rate 

in units of fired product (tph); and APCD parameter monitoring data. 

 

 FORM G -- MONITORING AND OTHER COSTS 

 Please provide the requested information for each facility. Indicate the Facility ID 

number using the same ID number indicated on other worksheets. In rows 8 through 12, provide 

the requested unit costs for January 2008 for each facility. If you provide unit costs for a 
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different period, please indicate the period in the appropriate cells. In rows 16 through 35, please 

estimate the total hours, frequency, and staff levels for each of the listed activities. In rows 39 

through 45, please provide the costs and other information for each stack test conducted during 

the past 3 years. Please also provide separately an itemized list of site preparation costs that are 

not included in the test cost estimate. Examples include the costs for drilling testing ports in the 

kiln stack and the costs for installing permanent access to sampling ports. 

 FORM H -- ECONOMIC IMPACTS INFORMATION 

 For each of the kilns entered on Form B, please enter the average selling price per ton for 

each of the products you listed on Form B for that kiln. Also enter the average labor rates for the 

staff levels listed. This information will be used to estimate the economic impacts of the final 

rule on specific facilities, companies, and the industry. 

 FORM I -- ADDITIONAL QUESTIONS 

 Please provide the requested information on control device costs, work practices, and 

periodic kiln operation. Also provide a process flow diagram for each facility. 
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Attachment 

List of Abbreviations used in Clay Ceramics Manufacturing ICR 

acfm actual cubic feet per minute 

APCD air pollution control device 

DIFF dry injection fabric filter 

DLA dry limestone adsorber 

DLS dry lime scrubber 

ft foot, feet 

ft2

 square feet 

gal gallon(s) 

gpd gallons per day 

gpm gallons per minute 

HAP hazardous air pollutant 

HCl hydrochloric acid 

HF hydrogen fluoride 

ICR information collection request 

hp horsepower 

hr hour(s) 

ID identification 

kwh kilowatt hour(s) 

MACT maximum achievable control technology 

NAICS North American Industry Classification System 

NG natural gas 

PM particulate matter 

SIC Standard Industrial Classification 

SO2 sulfur dioxide 

tph tons per hour 

yr year(s)