INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURING INDUSTRY

FORM A - GENERAL INFORMATION

Parent Company Information

Parent Company Acme Brick Company

Street Address- Line 1 3024 Acme Brick Plaza

Street Address- Line 2

City Ft Worth

State TX

Zip code 76109

Mailing Address (if different)- Line 1 P.O. Box 425

Mailing Address (if different)- Line 2

City Ft Worth

State TX

Zip code 76109

Number of Employees in Parent Company >500

Dun and Bradstreet number 85-872-3778

Facility Information

Facility 1 (1) Facility 2 (1) Facility 3 Facility 4 Facility 5 Facility 6 Facility 7 Facility 8 Facility 9 Facility 10 Facility 11 Facility 12 Facility 13 Facility 14 Facility 15

Facility ID ACME-1 ACME-2 ACME-3 ACME-4 ACME-5 ACME-6 ACME-7 ACME-8 ACME-9 ACME-10 ACME-11 ACME-12 ACME-13 ACME-14 ACME-15

Facility Name Acme - Ochs Brick Plant 

(AOP) Acme- Bennett Plant (BEP) Acme- Bennett Tunnel Plant (BTP)

Acme- Bridgeport Plant 

(BPP) Acme- Denton Plant (DTP) Acme- Denver Plant (DVP) Acme- Dixie Plant (DXP) Acme- Elgin Plant (ELP/ENP) Acme- Eureka Plant (EBP) Acme- Fort Smith Plant (FSP)

Acme- Garrison Plant 

(GAP)

Acme- Holly Springs Plant 

(HSP) Acme- Hope Brick Works Acme- Kanapolis Plant (KAP)

Acme- McQueeney Plant 

(MQP)

Address 1 915 East Rock Street 2350 Bennett Road 2350 Bennett Road 102 Main Street 220 E. Daniels Street 401 North Santa Fe Road 3457 Highway 792 FM Road 696 East Highway 64 2723 Old Greenwood Road 257 Brickyard Road 700 Hwy #7 N PO Box 663 1915 Avenue L FM 725

Address 2 --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

City Springfield Millsap Millsap Bridgeport Denton Castle Rock Jamestown Elgin Clarksville Fort Smith Garrison Holly Springs Hope Kanopolis McQueeney

County Brown Parker Parker Wise Denton Douglas Beinville Parish Travis Johnson Sebastian Nacogdoches Marshall Hempstead Ellsworth Guadalupe

State MN TX TX TX TX CO LA TX AR AR TX MS AR KS TX

Zip code 56087 76066 76066 76426 76205 80104 71045 78621 72830 72903 75946 38635 71802 67454 78123

Mailing Address (if different)- Line 1 --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

Mailing Address (if different)- Line 2 --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

City --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

State --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

Zip code --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

Number of employees at facility 64 41 62 45 200 75 0 115 70 63 57 60 0 40 72

What is your size classification for HAP 

emissions? Major source Major source Major source Major source Area Source (synthetic) Area Source (synthetic) Major source Major source Major source Major source Major source Major source Area Source (true)

Hours of operation for this facility (hr/yr) 8760 8760 8760 (2) 6570 8760 8760 0 8760 8760 8760 8760 8760 0 8760 8760

Facility's primary NAICS or SIC code 3251 3251 3251 3251 3251 3251 3251 3251 3251 3251 3251 3251 3251 3251 3251

Total Number of Periodic Kilns at this Facility 0 6 0 6 0 0 0 0 0 3 7 0 0 0 0

Total Number of Tunnel Kilns at this Facility 2 0 1 0 3 1 0 2 3 0 0 1 0 1 2

Contact Person for this ICR Garth Tayler Garth Tayler Garth Tayler Garth Tayler Garth Tayler Garth Tayler Garth Tayler Garth Tayler Garth Tayler Garth Tayler Garth Tayler Garth Tayler Garth Tayler Garth Tayler Garth Tayler

Contact Phone Number 817-870-8354 817-870-8354 817-870-8354 817-870-8354 817-870-8354 817-870-8354 817-870-8354 817-870-8354 817-870-8354 817-870-8354 817-870-8354 817-870-8354 817-870-8354 817-870-8354 817-870-8354

Contact Email Address gtayler@brick.com gtayler@brick.com gtayler@brick.com gtayler@brick.com gtayler@brick.com gtayler@brick.com gtayler@brick.com gtayler@brick.com gtayler@brick.com gtayler@brick.com gtayler@brick.com gtayler@brick.com gtayler@brick.com gtayler@brick.com gtayler@brick.com

1. These facilities are co-located. Facility 2 (6-periodic kilns); Facility 3 (1-tunnel kiln).

2. Facilities normally operate 8760 hrs/year. Facilities temporarily "idled" due to economic hardship.

090000648192f139

FORM A - General Information
Facility 16 Facility 17 Facility 18 Facility 19 Facility 20 Facility 21 Facility 22 Facility 23

ACME-16 ACME-17 ACME-18 ACME-19 ACME-20 ACME-21 ACME-22 ACME-23

Acme- Oklahoma City 

Plant OKP)

Acme- Ouachita Plant 

(OEP)

Acme- Pela Plant 

(PEP/PWP) Acme- San Felipe (SFP) Acme- Texas Clay Plant (TCP) Acme- Tulsa Plant (TUP) Acme- Weir Plant (WRP) Acme- Wheeler Plant (WTP)

500 E. Memorial Road Grigsby Ford Road US Highway 67 North 562 Peter San Felipe Road West Bartlett Street 4103 Dawson Road South Washington Street 2905 Dan Avenue

--- --- --- --- --- --- --- ---

Oklahoma City Malyern Malyern Sealy Malakoff Tulsa Weir Jonesboro

Oklahoma Hot Spring Hot Spring Austin Henderson Tulsa Cherokee Craighead

OK AR AR TX TX OK KS AR

73114 72104 72104 77474 75148 74115 66781 72403-0250

--- --- --- --- --- --- --- PO Box 250

--- --- --- --- --- --- --- ---

--- --- --- --- --- --- --- ---

--- --- --- --- --- --- --- ---

--- --- --- --- --- --- --- ---

58 59 111 104 233 75 36 39

Area Source (true) Area Source (synthetic) Major source Area Source (synthetic) Major source Major source Area Source (true) Major source

8760 8760 8760 8760 8760 8760 (2) 7665 8760

3251 3251 3251 3251 3251 3251 3251 3251

0 0 0 0 0 0 0 0

1 1 2 1 3 1 1 1

Garth Tayler Garth Tayler Garth Tayler Garth Tayler Garth Tayler Garth Tayler Garth Tayler Garth Tayler

817-870-8354 817-870-8354 817-870-8354 817-870-8354 817-870-8354 817-870-8354 817-870-8354 817-870-8354

gtayler@brick.com gtayler@brick.com gtayler@brick.com gtayler@brick.com gtayler@brick.com gtayler@brick.com gtayler@brick.com gtayler@brick.com

090000648192f139

FORM A - General Information
INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURING INDUSTRY

FORM B - KILN INFORMATION

ADDITIONAL INFORMATION ON PERIODIC KILNS

Facility ID

Kiln ID(s) [Use the ID 

from your permit or 

assign using TK-1, 2, 

etc for tunnel and 

PK-1,2, etc for 

periodic]

Reporting 

year (if not 

2007) Type of Kiln

If periodic, 

number of 

identical kilns 

included on this 

line Year Built

Stack 

Diameter 

(ft)

Major Products Types 

Fired in this Kiln (see 

list at bottom of 

spreadsheet)

Annual 

Operating 

Hours for Kiln

Does this kiln 

have an Air 

Pollution 

Control Device 

(APCD)?

 Full Design 

Capacity (tph)

Permitted 

Capacity (tph) 

if applicable

Actual 

Capacity 

Utilization (%) Primary Fuel Secondary Fuel

Percent Use of 

Secondary Fuel (% 

of operating time) Back-up Fuel

Reason(s) backup would be 

used (e.g., NG 

curtailment)

Total time backup fuel was 

used during 

year (hr)

Do you vent 

this kiln to a 

sawdust 

dryer?

Sawdust 

Dryer ID 

(Assign)

Total Number 

of kilns vented 

to this Dryer

Average percent of 

operating time this 

kiln vents to dryer

Average 

percent of flow 

sent to dryer

Kiln batch 

capacity 

(tons)

Average 

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 

(hr)

ACME-1 tk-1 Tunnel 1981 3.0 Face Brick 7665 No 6.25 9.9 65 Natural gas None na None No

ACME-1 tk-2 Tunnel 2001 3.0 Face Brick 7665 No 6.25 9.9 65 None na None No

ACME-2 EPN 18 Periodic 1970's 3.5 Face Brick 2907 No N/A 16293 (tpy) 54 Natural gas None na None No 246 51 57 6 7

ACME-2 EPN 19 Periodic 1970's 3.5 Face Brick 2907 No N/A 16293 (tpy) 54 Natural gas None na None No 246 51 57 6 7

ACME-2 EPN 20 Periodic 1970's 3.5 Face Brick 2907 No N/A 16293 (tpy) 54 Natural gas None na None No 246 51 57 6 7

ACME-2 EPN 21 Periodic 1970's 3.5 Face Brick 2907 No N/A 16293 (tpy) 54 Natural gas None na None No 246 51 57 6 7

ACME-2 EPN 22 Periodic 1970's 3.5 Face Brick 2907 No N/A 16293 (tpy) 54 Natural gas None na None No 246 51 57 6 7

ACME-2 EPN 23 Periodic 1970's 3.5 Face Brick 2907 No N/A 16293 (tpy) 54 Natural gas None na None No 246 51 57 6 7

ACME-3 EPN 30 Tunnel 1996 4.3 Shale Brick 8352 Yes 15.98 15.8 74 Natural gas None na None No

ACME-4 EPN 26 Periodic 1970's 4.2 Face Brick 3605 No N/A 18315 (tpy) 28 Natural gas None na None No 317 52 69 7 5

ACME-4 EPN 27 Periodic 1970's 4.2 Face Brick 3605 No N/A 18315 (tpy) 28 Natural gas None na None No 317 52 69 7 5

ACME-4 EPN 28 Periodic 1970's 4.2 Face Brick 3605 No N/A 18315 (tpy) 28 Natural gas None na None No 317 52 69 7 5

ACME-4 EPN 29 Periodic 1970's 4.2 Face Brick 3605 No N/A 18315 (tpy) 28 Natural gas None na None No 317 52 69 7 5

ACME-4 EPN 30 Periodic 1970's 4.2 Face Brick 3605 No N/A 18315 (tpy) 28 Natural gas None na None No 317 52 69 7 5

ACME-4 EPN 31 Periodic 1980's 4.2 Face Brick 3605 No N/A 18315 (tpy) 28 None na None No 317 52 69 7 5

ACME-5 Kiln A Tunnel 1960 3.3 Face Brick, architectural 8760 Yes 10.30 9.78 80 Natural gas None na None No

ACME-5 Kiln B Tunnel 1961 3.3 Face Brick, architectural 6570 Yes 10.30 9.78 61 Natural gas None na None No

ACME-5 Kiln C Tunnel 1962 3.3 Face Brick, architectural 8760 Yes 10.30 9.78 80 Natural gas None na None No

ACME-6 tk-1 Tunnel 1982 4.0 Face Brick 8760 Yes 11.99 12.56 56 Natural gas None na None No

ACME-7 SN-6

Periodicdemolished

ACME-7 SN-7

Periodicdemolished

ACME-7 SN-8

Periodicdemolished

ACME-8 tk-1 Tunnel 1961 1.8 Architectural 8400 No 10.00 9.9 73 Natural gas None na None No

ACME-8 tk-2 Tunnel 1999 3.3 Face Brick 8760 Yes 19.10 19.1 48 Natural gas None na None No

ACME-9 tk-4 Tunnel 1968 3.4 Face Brick 8760 No 3.99 6.0 84 Natural gas None na None No

ACME-9 tk-5 Tunnel 1970's 3.4 Face Brick 1416 No 3.99 6.0 15 Natural gas None na None No

ACME-9 tk-6 Tunnel 1970's 3.4 Face Brick 8760 No 3.99 6.0 73 Natural gas None na None No

ACME-10

Periodicdemolished

ACME-10

Periodicdemolished

ACME-10

Periodicdemolished

ACME-10

Periodicdemolished

ACME-10

Periodicdemolished

ACME-10

Periodicdemolished

ACME-10 SN17 Periodic 1999 3.5 Face Brick 4505 No N/A 23964 (tpy) 77 Natural gas None na None No 257 53 85 5 10

ACME-10 SN18 Periodic 1999 3.5 Face Brick 4505 No N/A 23964 (tpy) 77 Natural gas None na None No 257 53 85 5 10

ACME-10 SN19 Periodic 2000 3.5 Face Brick 4505 No N/A 23964 (tpy) 77 Natural gas None na None No 257 53 85 5 10

ACME-11 Kiln 1 Periodic 1970's 4.1 Face Brick 2736 No N/A 16440 (tpy) 49 Natural gas None na None No 232 48 57 6 9

ACME-11 Kiln 2 Periodic 1970's 4.1 Face Brick 2736 No N/A 16440 (tpy) 49 Natural gas None na None No 232 48 57 6 9

ACME-11 Kiln 3 Periodic 1970's 4.1 Face Brick 2736 No N/A 16440 (tpy) 49 Natural gas None na None No 232 48 57 6 9

ACME-11 Kiln 4 Periodic 1970's 4.1 Face Brick 2736 No N/A 16440 (tpy) 49 Natural gas None na None No 232 48 57 6 9

ACME-11 Kiln 5 Periodic 1970's 4.1 Face Brick 2736 No N/A 16440 (tpy) 49 Natural gas None na None No 232 48 57 6 9

ACME-11 Kiln 6 Periodic 1970's 4.1 Face Brick 2736 No N/A 16440 (tpy) 49 Natural gas None na None No 232 48 57 6 9

ACME-11 Kiln 7 Periodic 2001 4.1 Face Brick 2736 No N/A 16440 (tpy) 49 Natural gas na 232 48 57 6 9

ACME-12 Tunnel 1984 3.0 Face Brick 8760 No 8.45 9.9 56 Natural gas None na None No

ACME-13 tk-1

Tunneldemolished

ACME-13 tk-2

Tunneldemolished

ACME-14 tk-1 Tunnel 1954 3.0 Face Brick 8760 No 5.78 9.9 82 Natural gas None na None No

ACME-15 tk1 Tunnel 1945 2.0 Face Brick 8328 No 5.43 6.39 42 Natural gas None na None No

ACME-15 tk2 Tunnel 1956 2.0 Face Brick 8616 No 5.43 6.39 43 Natural gas None na None No

ACME-16 tk-1 Tunnel 1979 3.5 Face Brick 8760 No 13.54 20.55 93 Natural gas None na None No

ACME-17 tk-1 Tunnel 1981 4.0 Face Brick 6984 Yes 17.81 17.13 54 Natural gas None na None No

ACME-18 tk-1 Tunnel 1968 3.7 Architectural 8760 No 9.66 9.9 88 Natural gas None na None No

ACME-18 tk-2 Tunnel 1978 3.7 Face Brick 8760 No 7.86 9.9 67 Natural gas None na None No

ACME-19 tk-1 Tunnel 1984 3.9 Face Brick 5808 Yes 21.00 22.27 59 Natural gas None na None No

ACME-20 EPN 25 Tunnel 1960 4.4 Face Brick 8760 Yes 10.20 9.9 59 Natural gas None na None No

ACME-20 EPN 42 Tunnel 1962 4.4 Face Brick 0 No 5.10 5.59 65 Natural gas None na None No

ACME-20 EPN 44 Tunnel 1955 4.4 Face Brick 8760 No 5.10 5.59 26 Natural gas None na None No

ACME-21 EUG-3-3 Tunnel 1984 3.0 Architectural, Face Brick 8760 No 8.51 9.99 96 Natural gas None na None No

ACME-22 tk-1 Tunnel 1944 3.0 Face Brick 6720 No 4.45 3.84 63 Natural gas None na None No

ACME-23 SN-02 Tunnel 1978 2.5 Face Brick 8760 No 7.01 8.56 80 Natural gas None na None No

ACME-23

Periodicdemolished

ACME-23

Periodicdemolished

ACME-23

Periodicdemolished

ACME-23

Periodicdemolished

N/A - Not applicable

FACILITY and KILN IDs GENERAL INFORMATION KILN SIZE (a) FUEL USAGE FOR SAWDUST FIRED KILNS ONLY

090000648192f139

FORM B - Kiln Information

11/17/2014
INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURING INDUSTRY

FORM C - APCD INFORMATION

FACILITY AND KILN IDs

Facility ID

Kiln ID(s) [Use the ID 

from your permit or 

assign using TK-1, 2, 

etc for tunnel and PK1,2, etc for periodic]

Control ID # (assign 

based on ID used in 

Title V or using CD-1, 2, 

etc) Type

Reason Control 

was Installed

Number of kilns 

vented to this 

control device

Year control device 

was installed Reagent Type

Reagent feedrate 

(value) Units/ time Total fan hp

Total hp for other 

motors

Water usage 

(gpd)

Added cooling 

air, acfm

Other utility 

requirements Units/time Number of bags Bags- Length (ft) Bags- Width (ft) Bags- Diam (ft)

Bag- material of 

construction

Avg Life of bags 

(yrs) Cleaning method

ACME-17 tk-1 na

Dry Injection/Fabric Filter 

(DIFF)

Comply with 

MACT 1 2007

OEP Hydrated 

Lime 30 lbs / Hr 125 18.5 0 0

Compressed Air - 

30 CFM 450 19' 5 7/8" 0.5 1.57 Gore on Glass Unknown Pulse

ACME-19 tk-1 da-1

Dry Limestone Scrubber 

(DLA) Other 1 1991 SFP Limestone 86 lbs / Hr 50 40 0 0 N/A N/A 0 N/A N/A N/A N/A N/A N/A

ACME-20 tk-1 na

Dry Limestone Scrubber 

(DLA) Other 1 2000 TBP Limestone 1 Cubic Yards/Day 115 12 0 0 N/A N/A 0 N/A N/A N/A N/A N/A N/A

ACME-3 tk-1 dls-1 Dry Lime Scrubber (DLS) Other 1 1996

BTP Hydrated 

Lime 110 Lbs. Fresh lbs / Hr 125 75 2880 0 Compressed Air 390 16' 0.5 1.57075 Gore on Gore 5 Pulse

ACME-5 tk-1 na

Dry Injection/Fabric Filter 

(DIFF) Other 1 2005

DTP A Hydrated 

Lime 88 lbs / Hr 147.5 34 0 0 Compressed Air 588 16.4 N/A 0.5 Needle Felt PTFE 5 years Pulse

ACME-5 tk-2 na

Dry Injection/Fabric Filter 

(DIFF) Other 1 2005

DTP B Hydrated 

Lime 88 lbs / Hr 147.5 34 0 0 Compressed Air 588 16.4 N/A 0.5 Needle Felt PTFE 5 years Pulse

ACME-5 tk-3 na

Dry Injection/Fabric Filter 

(DIFF) Other 1 2005

DTP C Hydrated 

Lime 88 lbs / Hr 147.5 34 0 0 Compressed Air 588 16.4 N/A 0.5 Needle Felt PTFE 5 years Pulse

ACME-6 tk-1 dls-1 Dry Lime Scrubber (DLS) Other 1 1998

DVP Hydrated 

Lime 44 lbs / Hr 100 15 288 na Compressed Air 1152 8 0.5 0.5 Nomex 3 pulse

ACME-8 tk-2 na

Dry Injection/Fabric Filter 

(DIFF) Other 1 2002

ENP Hydrated 

Lime 135 lbs / Hr 150 16.5 0 6714

Compressed Air - 

45 CFM 675 14 0.5 1.57075 Gore on Glass 5 Pulse

N/A - Not Applicable

DESIGN AND OPERATING PARAMETERS BAGHOUSE/FABRIC FILTER (Stand-alone or as Part of DLS/DIFF system)

090000648192f139

FORM C - APCD Info 11/17/2014
INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURING INDUSTRY

FORM C - APCD INFORMATION

Facility ID

Kiln ID(s) [Use the ID 

from your permit or 

assign using TK-1, 2, 

etc for tunnel and PK1,2, etc for periodic]

ACME-17 tk-1

ACME-19 tk-1

ACME-20 tk-1

ACME-3 tk-1

ACME-5 tk-1

ACME-5 tk-2

ACME-5 tk-3

ACME-6 tk-1

ACME-8 tk-2

N/A - Not Applicable

WET SCRUBBER OTHER CONTROL (please identify parameters and units monitored to verify control is functioning properly)

Air-to-cloth ratio

Cost of full set of 

bags

Avg. compressed 

air requirements, 

acfm

Is reagent 

recirculated or 

one-pass?

If recirculated, 

average ratio of 

recirculated to 

fresh reagent

Number of 

cascades

Do you use 

reconditioning 

drum/peeler?

What is the rate 

at which 

limestone is 

removed from 

the system as 

waste?

If complying with 

the MACT, do 

you monitor 

pressure drop or 

use an 

alternative?

If complying with 

the MACT, how 

do you verify 

sufficient 

limestone in 

hopper?

Explain Other or 

Alternative

Type of scrubber 

(e.g., venturi)

Liquid flow rate 

(gal/min)

Pressure drop 

across scrubber 

(inches of water)

Design or 

Monitoring 

Parameter Units / Time

Design or 

Monitoring 

Parameter Units / Time

Design or 

Monitoring 

Parameter Units / Time

2.53:1 70000 30 One pass

N/A N/A N/A 6 (approx) No

N/A N/A N/A 6 Yes

3.0:1 225,000 Not Known Recirculated 225:1

165,191 approx 20 Recirculated 100:1

165,191 approx 20 Recirculated 100:1

165,191 approx 20 Recirculated 100:1

3.36:1 30,000 approx 30 Recirculated 99:1

3.25:1 60,750 45 One pass

DIFF or DLS DLA

090000648192f139

FORM C - APCD Info 11/17/2014
INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURING INDUSTRY

FORM D - TEST DATA

GENERAL INFORMATION TEST INFORMATION ADDITIONAL INFORMATION

FAC ID Control ID

Kiln/ Stack 

ID Test Date Report Date

Type of TestUncontrolled (or inlet to 

control), Controlled, 

Both HF HCl PM HAP Metals Other Reasons for Test

APCD Parameters Monitored 

During Test

Production rate of fired 

product during test (tph) Notes

ACME-10 na kiln 1 12/10/2003 Uncontrolled x x x state air permitting --- NA - Periodic Cost: $17,500

ACME-15 na kiln 1 10/14/2003 Uncontrolled x x x state air permitting --- 5.43 Cost: $7,245

ACME-16 na kiln 1 3/15/2002 Uncontrolled x x x state air permitting --- 13.5 Cost: approx $6,000

ACME-17 SN-07 SN-07 3/27/2007 Both x x x MACT Lime feed set point. 17.1 Cost: $35,000

ACME-19 EPN 1 EPN 16 4/12/2006 Both x x x state air permitting & MACT --- 21.08 Cost: $18,633

ACME-2 na kiln 5 2/14/2003 Uncontrolled x x x state air permitting --- NA - Periodic Cost: $20,940

ACME-20 EPN 25 EPN 25 3/26/2002 Both x x x state air permitting --- 10.2

ACME-21 na TUP 9/6/2002 Uncontrolled x x x state air permitting --- 8.5

ACME-3 EPN 30 EPN 30 10/5/2005 Both x x x MACT Lime feed set point. 16 Cost: $12,875

ACME-4 na kiln 3 5/21/2003 Uncontrolled x x x state air permitting --- NA - Periodic Cost: $19,845

ACME-5 EPN 21 EPN 21 9/9/2005 Controlled x x state air permitting --- 9.98 x 3kilns Cost: $36,340

ACME-6 Kiln 1 8/13/2003 x x x x state air permitting See stack test report 7.87

ACME-8 EPN 16 EPN 16 3/15/2007 Both x x x MACT Lime feed set point. 17.36 Cost: $24,520

This summary does not include test data from the 1998 EPA survey.

POLLUTANTS TESTED (Please put X in box to indicate pollutant 

was tested)

090000648192f139

FORM D - Test Data 11/17/2014
FACILITY: BTP ACME-3

Please provide the following information for January 2008, if available for your facility

Electricity cost, $/kwh 0.081

Reagent: Hydrated Lime

Reagent Cost, $/ton $120.78

(1) Waste Reagent disposal cost, $/ton $27.00

Water treatment costs, $/gal NA

Based on your experience complying with the now-vacated MACT, please provide as much information as possible below.

Activity Required by Activity Estimated Hours Frequency Staff Level

Develop a start-up, shutdown, and malfunction plan Develop plan and educate staff 45 Annually Managerial

Develop and implement an operating, maintenance, 

and monitoring plan Develop plan and educate staff 45 Annually Managerial

Bag replacement Replace single bag 2 Bi-annually Operator

Bag replacement Replace all bags 288 Every 5 years Maintenance

Maintain free-flowing lime (Describe action in next 

box and then add estimated burden) Maintaining vibrators 4 week Operator

Daily Maintenance (list activity(ies) in next column) Spreadsheet attached

Weekly 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)

Meet requirement to "maintain adequate amount 

of limestone in hopper." (Describe action taken in 

next box, then add estimated burden). If different 

approaches are taken at different plants, please add 

rows and provide information on each approach

Daily Maintenance (list activity(ies) in next column) Spreadsheet attached

Weekly 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)

Control Device: 

Compliance demonstration Activity (describe and 

estimate burden)

Compliance demonstration Activity (describe and 

estimate burden)

Compliance demonstration Activity (describe and 

estimate burden)

Daily Maintenance (list activity(ies) in next column)

Weekly 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)

Test Costs

Stack Test Year

Test Methods (please list all test methods 

conducted during stack test)

Uncontrolled 

(include 

uncontrolled 

stack or APCD 

inlet)? 

Controlled? 

Both? Cost ($)

Notes (Include Any 

site/preparation costs 

not included in 

estimate)

2005 See stack test report for full list Both 12,875

1. Spent lime is managed on-site

On-going Maintenance ( Please complete for one representative other control within your company. In lieu of completing this table, submit list of maintenance 

activities from your OMMP and provide estimate of hours/labor beside the table)

Please provide actual costs for stack tests you have conducted in the past three years. Please list all test methods included in the test

Standard Activities- DLA (limestone)

Standard Activities- Baghouse/DIFF/DLS

On-going Maintenance ( Please complete for one representative DIFF/DLS within your company. In lieu of completing this table, submit copy of maintenance 

activities from your OMMP and provide estimate of hours/labor beside the table)

Maintain a log of number of waste bags taken off per day and calculate the amount 

used.

On-going Maintenance ( Please complete for one representative DLA within your company. In lieu of completing this table, submit list of maintenance activities 

from your OMMP and provide estimate of hours/labor beside the table)

Standard Activities- Wet Scrubber or Other Control

090000648192f139

FORM E - Monit-Other Costs-BTP 11/17/2014
Scrubber PM's

Equipment Name Equipment Number Frequency Procedure Est. Hours Est. Dollars

Scrubber Pneumatic Lubricators 56AL 30 Days

1. Check and Fill 

lubricators(3) 1/2 hour $10 

2. Fill with 10WT oil

Induced Draft Fan 56FA0600 Quarterly

1. Grease fan shaft 

pillow block bearings 3 $60 

Procedair Scrubber 56CD0400 Bi-weekly 1. Check fluid levels 1/2 hour $10 

Anacaster Conveyor System 56RAL0100 Annually

1. Change oil in 

reducer 2 $80 

Bottom Rotary Airlock Feeder 56RAL0301 Weekly

1. Check purge air lines 

for leaks 1/2 hour $10 

2. Check fluid levels

Thomas conveyor and Dodge 

Electric Motor 56SR0300 Weekly

1. Grease flange 

bearings 1/2 hour $10 

2. Check reducer for 

leaks

Anacaster Conveyor System 56RAL0300 Annually

1. Change oil in 

reducer 2 $40 

Thomas conveyor and Dodge 

Electric Motor 56SR0200 Bi-weekly 1. Check fluid levels 1/2 hour $10 

Thomas conveyor and Dodge 

Electric Motor 56SR0600 Monthly

1. Lube and inspect 

drive chain 1 $20 

Thomas conveyor and Dodge 

Electric Motor 56SR0200 Annually

1. Change oil in 

reducer 1 $20 

2. Clean drain magnet

Thomas conveyor and Dodge 

Electric Motor 56SR0110 Annually

1. Change oil in 

reducer 1 $20 

2. Clean drain magnet

Bag house Waste Screw Feeder 56SR0110 Weekly 1. Check for leaks 1 $20 

2. Grease flange 

bearings

3. Check fluid levels

Rotary Airlock Feeder Baghouse 56SR0110 Bi-weekly 1. Check fluid levels 1/2 hour $10 

Thomas conveyor and Dodge 

Electric Motor 56SR0110 Monthly

1. Lube and inspect 

drive chain 1 $20 

Rotary Airlock Feeder Baghouse 56RAL0110 Weekly

1. Check purge air lines 

for leaks 1/2 hour $10 

Induced Draft Fan 56MD600 30 days

1. Check drive belts for 

tension,wear and 

cracks, tighten or 

replace as needed 1 $20 

2. Check sheaves for 

wear, loose bolts, or 

cracks

3. Grease bearings & 

check for excessive 

heat/vibration

CML Northern Blower 56FA0600 Weekly

1. Grease 16 fan 

damper bearings 3 $60 

2. Check belt appearance and tension

3. Inspect expansion joints

4. Feel for any normal vibration

5. Inspect pillow block bearings /remove guard for proper inspection

6. Co-ordinate bringing unit down w/burning supervisor and on duty burner
Facility: OEP ACME-17

Please provide the following information for January 2008, if available for your facility

Electricity cost, $/kwh 0.066

Reagent: Lime

Reagent Cost, $/ton 115.68

Waste Reagent disposal cost, $/ton 35

Water treatment costs, $/gal N/A

Based on your experience complying with the now-vacated MACT, please provide as much information as possible below.

Activity Required by Activity Estimated Hours Frequency Staff Level

Develop a start-up, shutdown, and malfunction plan Develop plan and educate staff 45 Annually Managerial

Develop and implement an operating, maintenance, 

and monitoring plan Develop plan and educate staff 45 Annually Managerial

Bag replacement Replace single bag 1.5 Yearly Managerial/Hourly

Bag replacement Replace all bags N/A

Maintain free-flowing lime (Describe action in next 

box and then add estimated burden)

Change Eductor and Inductor Tubes BiWeekly as 

well as keep the feed hose clear of obstructions. 

Change Lime Bags

2.75 Weekly Hourly

Daily Maintenance (list activity(ies) in next column) See Attached! 2.3 Weekly Managerial/Hourly

Weekly Maintenance (list activity(ies) in next 

column) See Attached! 0.5 Weekly Managerial/Hourly

Monthly Maintenance (list activity(ies) in next 

column) N/A

Semi-Annual Maintenance (list activity(ies) in next 

column) N/A

Yearly Maintenance (list activity(ies) in next column) Black Light Test 16 Yearly Managerial/Hourly

Other Frequency Maintenance (specify frequency 

and list activity(ies) in next column) Quarterly-See Attached

1.0 Quarterly

Managerial/Hourly

Meet requirement to "maintain adequate amount 

of limestone in hopper." (Describe action taken in 

next box, then add estimated burden). If different 

approaches are taken at different plants, please add 

rows and provide information on each approach

Daily Maintenance (list activity(ies) in next column)

Weekly 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)

Control Device: 

Compliance demonstration Activity (describe and 

estimate burden)

Compliance demonstration Activity (describe and 

estimate burden)

Compliance demonstration Activity (describe and 

estimate burden)

Daily Maintenance (list activity(ies) in next column)

Weekly 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)

Test Costs

Stack Test Year

Test Methods (please list all test methods 

conducted during stack test)

Uncontrolled 

(include 

uncontrolled 

stack or APCD 

inlet)? 

Controlled? 

Both? Cost ($)

Notes (Include Any 

site/preparation costs 

not included in 

estimate)

2007 FTIR Both 35000 NA

Please provide actual costs for stack tests you have conducted in the past three years. Please list all test methods included in the test

Standard Activities- Baghouse/DIFF/DLS

On-going Maintenance ( Please complete for one representative DIFF/DLS within your company. In lieu of completing this table, submit copy of maintenance 

activities from your OMMP and provide estimate of hours/labor beside the table)

Standard Activities- DLA (limestone)

On-going Maintenance ( Please complete for one representative DLA within your company. In lieu of completing this table, submit list of maintenance activities 

from your OMMP and provide estimate of hours/labor beside the table)

Standard Activities- Wet Scrubber or Other Control

On-going Maintenance ( Please complete for one representative other control within your company. In lieu of completing this table, submit list of maintenance 

activities from your OMMP and provide estimate of hours/labor beside the table)
DAILY

Date

Visible Emissions (Yes/No)

Limefeed Setting

Reagent Feed

Baghouse Dif. Pressure

Rotary Airlock

Lime Level in Bags

Drain Condensate from Air Filters

Listen for Access Door Seal Leaks

Check Compressor Pressure and Temp.

Check Compressed Air Dryer for Alarms

Listen for Compressed Air Leaks

WEEKLY

Date

Check all Pulse Hoses

Check Pulse Header Air Pressure

QUARTERLY

Date

Inspect Baghouse Clean Air Plenum for Signs 

of Broken Bags

Inspect Inside the Baghouse Hopper to Verify 

that Lime Build-Up is not Occuring

Blow the Baghouse Diff. Pressure Taps Clean
FACILITY: ENP ACME-8

Please provide the following information for January 2008, if available for your facility

Electricity cost, $/kwh .0688139/KWH

Reagent: Dry Lime

Reagent Cost, $/ton $107/Ton

(1) Waste Reagent disposal cost, $/ton $27

Water treatment costs, $/gal N/A

Based on your experience complying with the now-vacated MACT, please provide as much information as possible below.

Activity Required by Activity Estimated Hours Frequency Staff Level

Develop a start-up, shutdown, and malfunction plan Develop plan and educate staff 45 Annually Managerial

Develop and implement an operating, maintenance, 

and monitoring plan Develop plan and educate staff 45 Annually Managerial

Bag replacement Replace single bag 1.5 Yearly Managerial/Hourly

Bag replacement Replace all bags N/A

Maintain free-flowing lime (Describe action in next 

box and then add estimated burden)

Change Eductor and Inductor Tubes BiWeekly as 

well as keep the feed hose clear of obstructions. 

Change Lime Bags

2.75 Weekly Hourly

Daily Maintenance (list activity(ies) in next column) See Attached! 2.3 Weekly Managerial/Hourly

Weekly Maintenance (list activity(ies) in next 

column) See Attached! 0.5 Weekly Managerial/Hourly

Monthly Maintenance (list activity(ies) in next 

column) N/A

Semi-Annual Maintenance (list activity(ies) in next 

column) N/A

Yearly Maintenance (list activity(ies) in next column) N/A

Other Frequency Maintenance (specify frequency 

and list activity(ies) in next column) Quarterly-See Attached

1.0 Quarterly

Managerial/Hourly

Meet requirement to "maintain adequate amount 

of limestone in hopper." (Describe action taken in 

next box, then add estimated burden). If different 

approaches are taken at different plants, please add 

rows and provide information on each approach

Daily Maintenance (list activity(ies) in next column)

Weekly 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)

Control Device: 

Compliance demonstration Activity (describe and 

estimate burden)

Compliance demonstration Activity (describe and 

estimate burden)

Compliance demonstration Activity (describe and 

estimate burden)

Daily Maintenance (list activity(ies) in next column)

Weekly 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)

Test Costs

Stack Test Year

Test Methods (please list all test methods 

conducted during stack test)

Uncontrolled 

(include 

uncontrolled 

stack or APCD 

inlet)? 

Controlled? 

Both? Cost ($)

Notes (Include Any 

site/preparation costs 

not included in 

estimate)

2007 FTIR Testing Controlled $ 24,519

1. Spent lime is managed on-site.

Please provide actual costs for stack tests you have conducted in the past three years. Please list all test methods included in the test

Standard Activities- Baghouse/DIFF/DLS

On-going Maintenance ( Please complete for one representative DIFF/DLS within your company. In lieu of completing this table, submit copy of maintenance 

activities from your OMMP and provide estimate of hours/labor beside the table)

Standard Activities- DLA (limestone)

On-going Maintenance ( Please complete for one representative DLA within your company. In lieu of completing this table, submit list of maintenance activities 

from your OMMP and provide estimate of hours/labor beside the table)

Standard Activities- Wet Scrubber or Other Control

On-going Maintenance ( Please complete for one representative other control within your company. In lieu of completing this table, submit list of maintenance 

activities from your OMMP and provide estimate of hours/labor beside the table)
DAILY

Date

Visible Emissions (Yes/No)

Limefeed Setting

Reagent Feed

Baghouse Dif. Pressure

Rotary Airlock

Lime Level in Bags

Drain Condensate from Air Filters

Listen for Access Door Seal Leaks

Check Compressor Pressure and Temp.

Check Compressed Air Dryer for Alarms

Listen for Compressed Air Leaks

WEEKLY

Date

Check all Pulse Hoses

Check Pulse Header Air Pressure

QUARTERLY

Date

Inspect Baghouse Clean Air Plenum for Signs 

of Broken Bags

Inspect Inside the Baghouse Hopper to Verify 

that Lime Build-Up is not Occuring

Blow the Baghouse Diff. Pressure Taps Clean
INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURING INDUSTRY

FORM F - ECONOMICS IMPACTS INFORMATION

Product Selling Price Labor Rates as of January 2008

Confidential information provided in hard copy.

090000648192f139

FORM F -CONFIDENTIAL 11/17/2014
INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURING INDUSTRY

FORM G - ADDITIONAL QUESTIONS

Question 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

The actual cost estimates are confidential however the 

budgeted cost for installation of a DIFF control device at Acme 

Ouachita (Facility 17) was $1,532,310.11 and the actual install 

cost was $1,529,177.77. A DLS installation will cost 

approximately $2.0MM.

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. No.

3. Do you have any data available on the 

fluorine or chlorine contents of your raw 

materials? If yes, please explain the types of 

information you have, the test method used to 

determine these contents, the frequency in 

which you test your raw materials, and any 

other information you feel is relevant to this 

discussion. No.

4. If you answered YES to #3, please include 

copies of your raw material testing for either: 

the past two months OR the past 10 tests, 

whichever is more. Please indicate which you 

are submitted in the response section to this 

question. N/A

5. 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.) Also provide 

the additional information requested on Form 

B. Preheat - 40 hrs; Soak - 6-10 hrs; Cooling - 24 hrs.

6. If you operate periodic kilns, do you have any 

information regarding technological and/or 

economic limitations to testing those kilns?

Due to the fluctuations in temperature/flow/emission 

concentrations, stack testing is much more expensive than 

testing tunnel kilns since the testing occurs over the entire firing 

cycle of the kiln, which averages 50 hours.

7. Please provide a copy of a process flow 

diagram for your facility, if available. Not available.

090000648192f139

FORM G - Additional Questions 11/17/2014
These are the picklists for the other tables - this sheet will be hidden when the survey is sent to facilities.

CORPSIZE HAPSIZE KILNTYPE FUEL SECFUEL CONTROL REASON YESNO TESTS STAFF RECIR DLA1 DLA2 Yes

 0-99 Major source Tunnel Natural gas None

Dry Limestone 

Adsorber (DLA)

Comply with 

MACT Yes Uncontrolled Operator Recirculated

Pressure 

Drop

Daily climb to 

hopper

100-249 Area Source (true)

Tunnel- low profile or 

roller Sawdust

Natural 

gas

Dry Injection/Fabric 

Filter (DIFF)

Become 

Synthetic 

Minor No Controlled Maintenance One pass Alternative

Remote visual 

insp.

249-499 Area Source (synthetic) Tunnel-inactive Coal Sawdust

Dry Lime Scrubber 

(DLS) SO2 control Both Engineer

Fill/discharge 

records

>500 Not sure Periodic Fuel Oil Coal Wet Scrubber

Particulate/ 

opac. control Manager Other

Periodic-shuttle Landfill/Biogas Fuel Oil

Fabric Filter/ 

Baghouse only Other

Periodic-beehive Other Propane

Lime system 

(unsure if DIFF or 

DLS)

Landfilll/ 

Biogas

Spray Dryer/ 

Electrostatic 

Precipitator

Other Other