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 3.6 Yes Porcelain Tile 6058 17371 17371 76% Natural gas

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

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

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

FLOR-1 RK-5 Roller kiln 1995 2.08 Yes 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.

FACILITY and KILN IDs GENERAL INFORMATION KILN SIZE

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% 1371963 KG ≈ 576244 KG UNKNOWN

FLOR-1 GL-2 11 2005 3491 YES ≈ 42% 1371963 KG ≈ 576245 KG UNKNOWN

FLOR-1 GL-3 13 1996 3056 YES ≈ 42% 1201008 KG ≈ 504423 KG UNKNOWN

FLOR-1 GL-4 10 1996 3028 YES ≈ 42% 1190004 KG ≈ 499802 KG UNKNOWN

FLOR-1 GL-5 15 1996 3382 YES ≈ 42% 1329126 KG ≈ 558233 KG UNKNOWN

FLOR-1 GL-6 11 1996 3226 YES ≈ 42% 1267818 KG ≈ 532484 KG UNKNOWN

FLOR-1 GL-7 14 1996 2765 YES ≈ 42% 1086645 KG ≈ 456391 KG UNKNOWN

FLOR-1 GL-8 14 1996 2847 YES ≈ 42% 1118871 KG ≈ 469926 KG UNKNOWN

FLOR-1 GL-9 12 1996 2845 YES ≈ 42% 118085 KG ≈ 469596 KG UNKNOWN

FLOR-1 GL-10 13 1996 2851 YES ≈ 42% 1120443 KG ≈ 470586 KG UNKNOWN

FLOR-1 GL-11 13 1996 3005 YES ≈ 42% 1180965 KG ≈ 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

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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 3.6 CD-1

Dry Injection/Fabric Filter 

(DIFF) Other 1 2005

FLOR-1 RK-2, RK-3 3.6 CD-2

Dry Injection/Fabric Filter 

(DIFF) Other 2 2005

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

FACILITY and KILN IDs

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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 120 Once Manager

Develop and implement an operating, 

maintenance, and monitoring plan Develop plan and educate staff 120 Once Manager

Bag replacement Replace single bag 2 Monthly Maintenance

Bag replacement Replace all bags 256 Yearly 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 1 Daily 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 1 Daily Maintenance

Compliance demonstration Activity (describe and 

estimate hours, frequency, and staff level) Review and imput data 4 Monthly 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. 6 Semi-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 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)

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 19.11 N/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