11-0Y4035 

,to]DO 

P-i 

Return this infonnation reyuest ancl any additiona) information to: 

©ruce C. Jordan, birector 

Ctnission Standards bivision (MD-13) 

U. S. Environmental Protection Agency 

Office of Air Quality Plnnning and Standards 

Research Triangle Park. NC 27711 

Attention: E3ill Neuffer 

11. Generallnformation 

3 /qE3 

A. Name of legal owner of plant: •7annock Brick Group 

B. Name of (egal operator of plant, if different from legal owner: 

Tiffany Brick Co., L.P. dba US Brick 

C. Address of legal emmw/operator (please specify which): 8851 Hwy. 80 west 

D. Size of company: Fort Worth, TX 76116 

1. Approximate nurnber of employees of the business enterprise that owns this plant, 

including wliere applicable, the parent compatty and all subsidiaries, branches, 

and unrelated establisliments owned by the parent company (answer may be given 

tising the following ranges: 0-100; 101-250; 251-500; 501-750: 751-1.000; 

1.001-1,500; and > 1,5(lU) 

>1,500 

2. Number of plant eniployees attached to the brick and structural clay products 

manufacturing operation: 

1365 

E. Name of plant: US BRICK - MINERAL WELLS PLANT 

F. Street address of piant: 500 N. E. 1 4th Avenue, Mineral Wells, TX 76067 

G. Latitude and longitude coordinates of plant (see Appendix A of Attachment A): 

LAT. 32-48-56 LONG. 98-06-93 

11. Name of contact(s) ahle to answer technical questions about the completed survey: 

P11UL nNDERSON 

1. Titic(s): ASST . MGR . ENG .& RRS EARCH 

J. Telephone Numbcr: ( 9 4 0 ) 3 2 5-9 4 6 6 

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M. Plant Operations 

A. Complete Table 1 for the most recent calendar year (unless the respondent can justify 

selection of an alternate base year) for all processes at your plant that are covered by 

the brick and structural clay products manufacturing source category. For each type of 

process (i.e., process line), provide a process flow diagram that includes all sources of ✓ 

air emissions (e.g., stack emissions, process fugitive emissions, and area fugitive 

emissions [including fugitive dust emissions]). Also include all activities that generate 

HAP emissions, including the storage, transfer, handling, and processing of the 

materials, and wastewater and solid waste handling. 4ndicate all feedstocks, products, 

and emissions that contain compounds that are listed in Table 2, below. Use the same 

terminology/codes in identifying unit operations and emissions points in this figure as 

you will use in completing Table 3, below. 

B. List the products, coproducts, and by-products identified in the process flow diagram 

and indicate for each how much is produced annually. 

199,028 Tons Face Brick 

IV. HAP's--Usage and Emissions 

A. Complete Table 2 for each emission point identified in the process flow diagram(s) 

developed for Part III.A., above. For each HAP listed on the table, indicate the 

likelihood, using the codes defined in Table 2, that the HAP is emitted from a given 

emission point within the source category. Identif} ► the appropriate emission points 

using the same terminology/codes you used in completing the process flow diagram(s) 

in Part QI.A, above. 

B. Using copies of Tables 3A and 313, complete the table for each process and emission 

point identified in Part IQ, with the following exceptions. 

1. For those emission points from units with Resource Conservation and Recovery 

Act (RCRA) Part B permits, it is not necessary to complete Table 3 for 

wastewater and solid waste handling operations; 

2. Sources with no air pollution capture or control systems will only complete 

colutnns 1-3, 8, and 10 of Table 3-A; and 

3. Provide HAP data only for those HAP's identified with code "A" in Table 2, 

above. 

C. Complete Table 4 for any air pollution capture or control equipment identified in 

Table 3, above. 

2 
4 

D. For calculations based on emission factors, material balances, or engineering 

principles, submit a step-by-step description of the calculations, including assumptions 

used, and a brief rationale for the validity of the calculation method used. (See 

guidance documents listed in Attachment A, Section IV). If test reports are listed as 

the basis for emissions estimates or capture system and control device efficiencies, 

provide a brief summary of the relevant tests. Include. information such as the purpose 

of the test, when it was conducted, what test methods were used, and information on 

the process operation during the test. It is not necessary to submit copies of actual test 

reports at this time although EPA may request additional documentation on a plantspecific basis in the future. 

V. Factors That Affect HAP Eniission Reductions 

Completion of this Section V is optional. If you choose to respond, clearly distinguish 

between pollution reduction and source reduction measures. Pollution reduction measures 

alter the physical, chemical, or biological characteristics or the volume of a HAP through a 

process or activity which itself is not integral to and necessary to produce a product or 

provide a service. The use of "add-on" devices to capture and control (recover or destroy) 

HAP emissions are considered pollution reduction measures. In contrast, source reduction 

measures reduce the amount of any HAP prior to recycling, treatment, or disposal. Source 

reduction measures include equipment or technology modifications, process or procedure 

modifications, reformulation or redesign of products, substitution of raw materials, and 

improvements in housekeeping, maintenance, training, or inventory control. 

A. For each unit operation for which pollution reduction or source reduction 

measures have resulted in a decrease in HAP emissions since 1987, provide the 

following information. 

1. Name of unit operation: 

2. Type of control or description of process change: 

B. I:f recovery or recycling of feedstocks is used, quantify the effect of the program (e.g., 

estimated annual purchase of feedstock in the absence of recovery/recycling compared 

to actual annual purchase): 

1// 
C. Are you aware of any alternative processes (feedstock substitutions or eliminations) or 

control devices that could result in fewer impacts between environmental media 

(water, air, and land) or reduced total release to all environmental media (e.g., reduced 

wastewater or solid wa.ste)? Discuss whether these processes could be adapted to the 

brick and structural clay products manufacturing source category and any experience 

you have with them. , . 

VI. Miscellaneous 

A. If any control or process change described in Part V was instituted as a result of new 

source review requirements pursuant to 40 CFR 51.160, Subpart I, Review of New 

Sources and Modifications, provide the date at which the lowest achievable emission 

rate (LAER) came into effect: 

B. Describe any factors not addressed in the above questions that might serve to 

distinguish your facility from others in this source category for purposes of developing 

a separate source category or subcategory and MACT standards. 

J:XDMSW8001o\BRICK\BRIK-GEN.WPD 

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JUNE 1S POST-C4NTROL DEV1l;E NOST 

1 DFC 1990 .11.it1F 1993 CnPJTRf1L 

K I1-N td0. 1 RAT IO TO 'K 1CN td0. 1 PERCEtJT 

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<0.143 <0.145 <0.141 

<0.0040 <0.0041 <0.0041 

Table 11 Continued 

VOC ae C3H8 

Concentration, ppm 

Emiseione, lbe/hr 

SULFUR DIOXIDE 

Concentration, ppm 

Emiseione, lbe/hr 

HYDROGEN FLUORIDE 

Sample Weight, mg 

Concentration, ppm 

Emiseione, lbe/hr 

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Table N2 Continued 

VOC as C3H8 

Concentration, ppm 

Emissions, lbs/hr 

SULFUR DIOXIDE 

Concentration, ppm 

Emissions, lbs/hr 

HYDROGEN FLUORIDE 

Sample Weight, mg 

Concentration, ppm 

Emissions, lbs/hr 

3.199 3.807 5.462 

0.231 0.272 0.375 

113.5 140.8 161.7 

11.93 14.63 16.15 

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y ~~ 
US BRICK - MINERAL WELLS PLANT 

TABLE 1 The identified HAP (Hazardous Air Pollutant) emission from the brick plant is 

from the tunnel kilns. I'lie production pounds are listed at Tons/Year. The 

average production is the 1997 production. The maximum production is based on 

the air permit limitations. The age on the facility is the years since the kiln was 

built. The economic life of the plant is determined by any future innovations or 

changes in the brick industry that would make the operation of the plant cost 

prohibitive. 

TABLE 2 l lydrogen Fluoride is the only identi[ied HAP from tlie brick process. 

TABLE 3-B The HF is removed from the kiln exhaust gasses in a dry lime pollution device. 

Elydrated lime is blown into the gas stream to react with the (luorides. The 

reacted lime is then removed from the gas stream in a hot baghouse. The 

efficiency of the system was not documented during the initial testing of the unit 

because there is no test ports up-stream of the unit. The Texas Natural Resource 

Conservation Commission estimated the efficiency at +99%. They compared the 

1993 compliance test to an uneontrolled test done in 1990. Their evaluation is 

attached. The air perinit required 95% removal of fiF. 

The 1997 emissions are pro-rated from the compliance test done in 1993. The 

1993 stack test is the emissions from a 13 car push. The average push in 1997 

was 12.4 cars. I'he HAP emissions from the kiln is proportional to the amount of 

product produced. Calculations are attached. 

TABLE 4 The baghouse is the closest approximation to the system installed at the plant. 

~~