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

**FORM A - GENERAL INFORMATION**
**Parent Company Information** Parent Company Florim Ceramiche SpA Street Address - Line 1 Via Canaletto 24 Street Address - Line 2 41042 Fiorano (MO) Italy 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 >500 Dun and Bradstreet number 42-810-2487

**Facility Information** Facility 1 Facility 2 Facility 3 Facility 4 Facility 5 Facility 6 Facility 7 Facility ID FLOR-1 Facility Name Florim USA Address 1 300 International Blvd Address 2 City Clarksville County Montgomery State Tennessee Zip code 37040 Mailing Address (if different) - Line 1 Mailing Address (if different) - Line 2 City State Zip code Number of employees at facility 250-499 What is your size classification for HAP emissions? Major source Hours of operation for this facility (hr/yr) Facility's primary NAICS or SIC code 3253 Total Number of Periodic Kilns at this Facility 0 Total Number of Tunnel Kilns at this Facility 0 Contact Person for this ICR Connie O'Neal Contact Phone Number 931-553-7595 Contact Email Address cjames@aol.com

09000064819353d4 FORM A - General Information 12/1/2014

### INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY **INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY FORM B - KILN INFORMATION** 

Facility ID Kiln ID(s)[Use the

ID from your permit or assign using TK-1,2, etc for tunnel, RK1, 2, etc for roller, and PK-1, 2, etc for periodic] Reporting Year (if

not 2007) Type of Kiln If periodic, number of identical kilns on this line Year Built Stack Diameter (ft) Does this kiln

have an Air Pollution Control Device (APCD)? Major Product Types Fired in Kiln Annual

Operating Hours for Kiln Full Design

Capacity (tph) Permitted

Capacity (tph) if applicable Average/Actual

Capacity Utilization (%) **(a)** Primary Fuel

FLOR-1 RK-1 Roller kiln 2005 3.6Yes Porcelain Tile 6058 17371 17371 76%Natural gas

FLOR-1 RK-2 Roller kiln 1995 2.08Yes Porcelain Tile 3281 8025 13405 34%Natural gas

FLOR-1 RK-3 Roller kiln 1995 2.08Yes Porcelain Tile 3282 8025 13405 34%Natural gas

FLOR-1 RK-4 Roller kiln 1995 2.08Yes Porcelain Tile 3661 8025 13405 73%Natural gas

FLOR-1 RK-5 Roller kiln 1995 2.08Yes Porcelain Tile 3691 8025 13405 73%Natural gas

**(a) 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.**  KILN SIZE FACILITY and KILN IDs GENERAL INFORMATION

09000064819353d4 FORM B - Kiln Information 12/1/2014

### INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY **INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY FORM B - KILN INFORMATION** 

Facility ID Kiln ID(s)[Use the

ID from your permit or assign using TK-1,2, etc for tunnel, RK1, 2, etc for roller, and PK-1, 2, etc for periodic]

FLOR-1 RK-1

FLOR-1 RK-2

FLOR-1 RK-3

FLOR-1 RK-4

FLOR-1 RK-5

**(a) 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.**  FACILITY and KILN IDs ADDITIONAL INFORMATION ON PERIODIC KILNS

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) 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)

Propane NG Curtailment 0

Propane NG Curtailment 0

Propane NG Curtailment 0

Propane NG Curtailment 0

Propane NG Curtailment 0 FUEL USAGE

09000064819353d4 FORM B - Kiln Information 12/1/2014

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

**FORM C - GLAZE APPLICATION INFORMATION** GENERAL INFORMATION

Facility ID Glaze Line ID(s)

[Use the ID from your permit or assign using GZ-1, 2, etc] Number of Spray

Booths Per Line Reporting Year (if

not 2007) Year Built Annual Operating Hours for Glaze Line Is this Glaze Line Controlled by

an Air Pollution Control Device

(APCD)? Average

Percentage of HAP's Contained in Glazes (a) 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) FLOR-1 GL-1 9 2005 3491 YES ≈42% 1371963KG ≈ 576244 KG UNKNOWN FLOR-1 GL-2 11 2005 3491 YES ≈42% 1371963KG ≈ 576245 KG UNKNOWN FLOR-1 GL-3 13 1996 3056 YES ≈42% 1201008KG ≈ 504423 KG UNKNOWN FLOR-1 GL-4 10 1996 3028 YES ≈42% 1190004KG ≈ 499802 KG UNKNOWN FLOR-1 GL-5 15 1996 3382 YES ≈42% 1329126KG ≈ 558233 KG UNKNOWN FLOR-1 GL-6 11 1996 3226 YES ≈42% 1267818KG ≈ 532484 KG UNKNOWN FLOR-1 GL-7 14 1996 2765 YES ≈42% 1086645KG ≈ 456391 KG UNKNOWN FLOR-1 GL-8 14 1996 2847 YES ≈42% 1118871KG ≈ 469926 KG UNKNOWN FLOR-1 GL-9 12 1996 2845 YES ≈42% 118085KG ≈ 469596 KG UNKNOWN FLOR-1 GL-10 13 1996 2851 YES ≈42% 1120443KG ≈ 470586 KG UNKNOWN FLOR-1 GL-11 13 1996 3005 YES ≈42% 1180965KG ≈ 496005 KG UNKNOWN FACILITY and GLAZE LINE IDs

**(a) A "HAP containing glaze" is any glaze that contains a material or ingredient listed as a metal HAP on the MSDS for that glaze/material.** PLANTWIDE GLAZE USE

09000064819353d4 FORM C - Glaze Line Info 12/1/2014**INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY**  **FORM D - KILN APCD INFORMATION**

APCD Information BAGHOUSE/FABRIC FILTER (Stand-alone or as part of DIFF or DLS)

Facility ID Kiln ID(s) [Use the ID

from your permit or assign using TK-1, 2, etc for tunnel, RK-1, 2, etc for roller, and PK-1, 2, etc for periodic] Stack Diameter (ft) 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 Total bag surface

area (ft2) Bag- material of

construction Avg Life of bags

(yrs) Air-to-Cloth Ratio

(see instructions) Cleaning method

FLOR-1 RK-1 3.6CD-1 Dry Injection/Fabric Filter (DIFF) Other 1 2005

FLOR-1 RK-2, RK-3 3.6CD-2 Dry Injection/Fabric Filter (DIFF) Other 2 2005

FLOR-1 RK-4, RK-5 3.6CD-3 Dry Lime Scrubber (DLS) Other 2 2005 FACILITY and KILN IDs

09000064819353d4 FORM D - Kiln APCD Info 12/1/2014**INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY**  **FORM D - KILN APCD INFORMATION**

Facility ID Kiln ID(s) [Use the ID

from your permit or assign using TK-1, 2, etc for tunnel, RK-1, 2, etc for roller, and PK-1, 2, etc for periodic]

FLOR-1 RK-1

FLOR-1 RK-2, RK-3

FLOR-1 RK-4, RK-5 FACILITY and KILN IDs DLS or DIFF DLA

Reagent Type Reagent feedrate

(value) Units/ time Total annual reagent usage (indicate units) 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? Parameter

monitored Monitoring

frequency Type of scrubber

(e.g., venturi) Liquid flow rate

(gal/min)

Lime Continuous One pass

Lime Continuous One pass

Lime Continuous One pass

09000064819353d4 FORM D - Kiln APCD Info 12/1/2014**INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY**  **FORM D - KILN APCD INFORMATION**

Facility ID Kiln ID(s) [Use the ID

from your permit or assign using TK-1, 2, etc for tunnel, RK-1, 2, etc for roller, and PK-1, 2, etc for periodic]

FLOR-1 RK-1

FLOR-1 RK-2, RK-3

FLOR-1 RK-4, RK-5 FACILITY and KILN IDs OTHER CONTROL (please identify parameters and units monitored to verify control is functioning properly)

Pressure drop across scrubber (inches of water) pH range of

scrubbing liquid Reagents used to

maintain pH in desired range Total annual

reagent usage (indicate units) Units / Time Design or Monitoring Parameter Units / Time Design or Monitoring Parameter Units / Time Design or Monitoring Parameter Units / Time

09000064819353d4 FORM D - Kiln APCD Info 12/1/2014**INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY**  **FORM E - GLAZE LINE APCD INFORMATION** FACILITY and GLAZE LINE IDs CONTROL DEVICE INFORMATION BAGHOUSE/FABRIC FILTER WET SCRUBBER

Facility ID Glaze Line ID(s) [Use

the ID from your permit or assign using GZ-1, 2, etc] Control ID # (assign

based on ID used in Title V or using CD-1, 2, etc) Type Reason Control was Installed Number of spray

booths vented to this control device Year control

device was installed Total bag surface

area (ft2) Bag- material of

construction Avg Life of bags

(yrs) Cleaning method Type of scrubber (e.g., venturi) Liquid flow rate

(gal/min)

FLOR-1 GL-1, GL-2 CD-1 Fabric filter Other 20 2005 1840 Woven polyester 1 Pulse jet FLOR-1 GL-3, GL-4, GL-5 CD-2 Wet scrubber Other 38 1996 Venturi 132 FLOR-1 GL-6, GL-7, GL-8 CD-3 Wet scrubber Other 39 1996 Venturi 132 FLOR-1 GL-9, GL-10, GL-11 CD-4 Wet scrubber Other 38 1996 Venturi 132

09000064819353d4 FORM E - Glaze Line APCD Info 12/1/2014**INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY**  **FORM E - GLAZE LINE APCD INFORMATION** FACILITY and GLAZE LINE IDs

Facility ID Glaze Line ID(s) [Use

the ID from your permit or assign using GZ-1, 2, etc]

FLOR-1 GL-1, GL-2 FLOR-1 GL-3, GL-4, GL-5 FLOR-1 GL-6, GL-7, GL-8 FLOR-1 GL-9, GL-10, GL-11 WATER CURTAIN OTHER CONTROL (please identify parameters and units monitored to verify control is functioning properly)

Pressure drop across scrubber (inches of water) Water flow rate

(gal/min) Width of water

curtain (ft) Equipped with

baffle or mist eliminator? Design or

Monitoring Parameter Units / Time Design or Monitoring Parameter Units / Time Design or Monitoring Parameter Units / Time

N/A N/A N/A

09000064819353d4 FORM E - Glaze Line APCD Info 12/1/2014**INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY**

**FORM F - TEST DATA**

GENERAL INFORMATION TEST INFORMATION ADDITIONAL INFORMATION

FAC ID Control ID Kiln/Glaze Line/ Stack ID Test Date Report Date Type of TestUncontrolled (or inlet to control), Controlled, Both HF HCl PM HAP Metals Other (list below) Other (list

below) Other (list

below) Reasons for Test APCD Parameters Monitored During Test Notes POLLUTANTS TESTED (Please put X in box to indicate pollutant was tested)



### 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.

09000064819353d4 FORM F - Test Data 12/1/2014**INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY**

**FORM G - MONITORING AND OTHER COSTS**

**Facility ID** FLOR-1

**Unit Costs for January 2008**

Parameter Cost Electricity cost, $/kwh $16.09 / kwh Reagent: Lime Reagent Cost, $/ton $117 / ton Waste Reagent disposal cost, $/ton or $/year ≈$14719 / year Water treatment costs, $/gal Recycle water, nominal cost

Activity Required by Activity Estimated Hours Frequency Staff Level Develop a start-up, shutdown, and malfunction plan Develop plan and educate staff 120Once Manager Develop and implement an operating, maintenance, and monitoring plan Develop plan and educate staff 120Once Manager
Bag replacement Replace single bag 2Monthly Maintenance Bag replacement Replace all bags 256Yearly Maintenance Maintain free-flowing lime (Describe action in next box and then add estimated hours, frequency, and staff level) Check piping for obstructions, clear any if found 1Daily Maintenance
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) Record scrubber flow rates/ bag house pressure drops 1Daily Maintenance
Compliance demonstration Activity (describe and estimate hours, frequency, and staff level) Review and imput data 4Monthly Manager
Compliance demonstration Activity (describe and estimate hours, frequency, and staff level)

Daily Maintenance (list activity(ies) in next column) Verify operation is correct, chart all readings, fill out check list, fix any problems found, check emissions, notify team leader or manager of any issues, file paperwork. Daily Maintenance Weekly Maintenance (list activity(ies) in next column)
Monthly Maintenance (list activity(ies) in next column) Grease all points, notify teamleader or manager of any problems, file paperwork. 12 Monthly Maintenance

Semi-Annual Maintenance (list activity(ies) in next column) Inspect structure, fan, pulleys, belts and fan wheel. Any prob;ems found notify teamleader or manager. File records. 6Semi-Annual Maintenance 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 alltest 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) No current stack test data available.

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- DLA (limestone) Standard Activities- Baghouse/DIFF/DLS

Standard Activities- All Controls Standard Activities- Wet Scrubber or Other Control

09000064819353d4 FORM G - Monit-Other Costs 12/1/2014

## INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY

**FORM H - ECONOMICS IMPACTS INFORMATION**

Product Selling Price Labor Rates as of January 2008

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 FLOR-1 Porcelain Tile $517 13.08 19.11N/A 31.19

09000064819353d4 Form H - Economics Info 12/1/2014

# INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY **FORM I - 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 estimated final cost for the installation of the lime injected baghouse in 2005 was $200,000. This cost included the equipment, installation, installation of piping system and training. 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. 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.) N/A 4. If you operate periodic kilns, do you have any information regarding technological and/or economic limitations to testing those kilns? N/A 5. Please provide a copy of a process flow diagram for your facility, if available. Please See Attachment A

09000064819353d4 FORM I - Additional Questions 12/1/2014