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

**FORM A - GENERAL INFORMATION**
**Parent Company Information** Parent Company Street Address - Line 1 Street Address - Line 2 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 Dun and Bradstreet number

**Facility Information** Facility 1 Facility 2 Facility 3 Facility 4 Facility 5 Facility 6 Facility 7 Facility ID Facility Name Stonepeak Ceramics, Inc. Address 1 238 Porcelain Tile Drive Address 2 City Crossville County Cumberland State TN Zip code 38555 Mailing Address (if different) - Line 1 Mailing Address (if different) - Line 2 City State Zip code Number of employees at facility 100-249 What is your size classification for HAP emissions? Not sure Hours of operation for this facility (hr/yr) 7525 Facility's primary NAICS or SIC code 327122 Total Number of Periodic Kilns at this Facility 0 Total Number of Tunnel Kilns at this Facility 0 Contact Person for this ICR William Smith Contact Phone Number (931) 459-2509 Contact Email Address wsmith@stonepeakceramics.com

09000064819353ef 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 IDKiln ID(s)[Use theID

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] 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 applicableAverage/Actual

Capacity Utilization (%) **(a)** Primary Fuel 18-0210 RK1 Roller kiln 2003 Yes Clay Ceramics 1330 19.3 32Natural gas 18-0210 RK2 Roller kiln 2003 Yes Clay Ceramics 4526.5 19.3 33Natural gas 18-0210 RK3 Roller kiln 2007 Yes Clay Ceramics 3810.9 19.3 33Natural 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.**  GENERAL INFORMATION FACILITY and KILN IDs KILN SIZE

09000064819353ef 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 IDKiln ID(s)[Use theID

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] 18-0210 RK1 18-0210 RK2 18-0210 RK3

**(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 FuelReason(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) None n/a None n/a n/a n/a n/a n/a n/a n/a None n/a None n/a n/a n/a n/a n/a n/a n/a None n/a None n/a n/a n/a n/a n/a n/a n/a FUEL USAGE

09000064819353ef 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

ConsumptionAnnual Consumption Units (H)*(I)

.... Annual Total of HAPs In Glazes HAPs In Glazes

Units % of HAP

Containing Glazes that are spray applied (if known) 18-0120 GZ-0 3 2007 2004 1085.5Yes <.01% 808.5 Do Not Know 18-0120 GZ-1 3 2007 2004 1085.5Yes <.01% 808.5 Do Not Know 18-0120 GZ-2 2 2007 2004 1085.5Yes <.01% 808.5 Do Not Know 18-0120 GZ-3 2 2007 2004 1085.5Yes <.01% 808.5 Do Not Know 18-0120 GZ-4 1 2007 2004 1085.5Yes <.01% 808.5 Do Not Know 18-0120 GZ-5 1 2007 2004 1085.5Yes <.01% 808.5 Do Not Know lbs 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

09000064819353ef 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 IDKiln 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

18-0120 RK1 3.7Baghouse # 11 Dry Injection/Fabric Filter (DIFF) Comply with MACT 1 2004 Nomex Teflonato FTI 400 g/mg 5 Pressurized air shoots material to recycling area using a propulser

18-0120 RK2 3.7Baghouse # 12 Dry Injection/Fabric Filter (DIFF) Comply with MACT 1 2004 Nomex Teflonato FTI 400 g/mg 5 Pressurized air shoots material to recycling area using a propulser

18-0120 RK3 2.6Baghouse # 13 Dry Injection/Fabric Filter (DIFF) Comply with MACT 1 2006 Nomex Teflonato FTI 400 g/mg 5 Pressurized air shoots material to recycling area using a propulser

For control of fluoride compounds - comply with MACT for overall compliance FACILITY and KILN IDs

09000064819353ef 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 IDKiln 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]

18-0120 RK1

18-0120 RK2

18-0120 RK3 FACILITY and KILN IDs DLS or DIFF DLA

Reagent TypeReagent 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)

no n/a n/a n/a n/a n/a No n/a Pressure Drop continuously n/a n/a

no n/a n/a n/a n/a n/a No n/a Pressure Drop continuously n/a n/a

no n/a n/a n/a n/a n/a No n/a Pressure Drop continuously n/a n/a

09000064819353ef 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 IDKiln 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]

18-0120 RK1

18-0120 RK2

18-0120 RK3 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 liquidReagents 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

n/a n/a n/a n/a n/a Daily checks visually; pressure drop 6 times a day;

continuously monthly records

of operation monthly lime feed measured; visual check of lime feed once a day; 2

times a day

n/a n/a n/a n/a n/a Daily checks visually; pressure drop 6 times a day;

continuously monthly records

of operation monthly lime feed measured; visual check of lime feed once a day; 2

times a day

n/a n/a n/a n/a n/a Daily checks visually; pressure drop 6 times a day;

continuously monthly records

of operation monthly lime feed measured; visual check of lime feed once a day; 2

times a day

09000064819353ef 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 IDGlaze 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)

18-0120 GZ-0 E-9,E-8, & E-16 Fabric filter Comply with MACT 3 2004 polyester felt 500 g/mg 5 pressurized air shoots material to recycling area in raw materials using a propulser n/a

18-0120 GZ-1 E-9,E-8, & E-16 Fabric filter Comply with MACT 3 2004 polyester felt 500 g/mg 5 pressurized air shoots material to recycling area in raw materials using a propulser n/a

18-0120 GZ-2 E-9,E-8, & E-16 Fabric filter Comply with MACT 2 2004 polyester felt 500 g/mg 5 pressurized air shoots material to recycling area in raw materials using a propulser n/a

18-0120 GZ-3 E-9,E-8, & E-16 Fabric filter Comply with MACT 2 2004 polyester felt 500 g/mg 5 pressurized air shoots material to recycling area in raw materials using a propulser n/a

18-0120 GZ-4 E-9,E-8, & E-16 Fabric filter Comply with MACT 1 2004 polyester felt 500 g/mg 5 pressurized air shoots material to recycling area in raw materials using a propulser n/a

18-0120 GZ-5 E-9,E-8, & E-16 Fabric filter Comply with MACT 1 2004 polyester felt 500 g/mg 5 pressurized air shoots material to recycling area in raw materials using a propulser n/a

To control 99+% of particulate to return to process for compliance 124mm diameter x 2510 mm length

09000064819353ef 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 IDGlaze Line ID(s) [Use

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

18-0120 GZ-0

18-0120 GZ-1

18-0120 GZ-2

18-0120 GZ-3

18-0120 GZ-4

18-0120 GZ-5 WATER CURTAIN OTHER CONTROL (please identify parameters and units monitored to verify control is functioning properly)

Liquid flow rate (gal/min) 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 visually monitored 6 times a day pressure drop continuously monthly records of operation monthly

n/a visually monitored 6 times a day pressure drop continuously monthly records of operation monthly

n/a visually monitored 6 times a day pressure drop continuously monthly records of operation monthly

n/a visually monitored 6 times a day pressure drop continuously monthly records of operation monthly

n/a visually monitored 6 times a day pressure drop continuously monthly records of operation monthly

n/a visually monitored 6 times a day pressure drop continuously monthly records of operation monthly

09000064819353ef 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

18-0120RK1 Baghouse #11 10/12/2005 10/9/2006 Controlled X X CO, NOx, SO2, VOC Compliance HF, HCl, CO, Nox, SO2, VOC - measured to see if within permit status

18-0120RK2 Baghouse #12 10/12/2005 10/9/2006 Controlled X X CO, NOx, SO2, VOC Compliance HF, HCl, CO, Nox, SO2, VOC - measured to see if within permit status

18-0120RK3 Baghouse #13 10/12/2005 10/9/2006 Controlled X X CO, NOx, SO2, VOC Compliance HF, HCl, CO, Nox, SO2, VOC - measured to see if within permit status

18-0120Vertical

Dryers 0-5 Baghouse #8/1 10/10/2005 10/9/2006 Controlled X CO, NOx, SO2, VOC Compliance PM, SO2, Nox, VOC, CO measured to see if within permit status

18-0120A1 Baghouse # 3 & #5 10/11/2005 10/9/2006 Controlled X CO, NOx, SO2, VOC Compliance PM, SO2, Nox, VOC, CO measured to see if within permit status

18-0120A2 Baghouse # 3 & #5 10/11/2005 10/9/2006 Controlled X CO, NOx, SO2, VOC Compliance PM, SO2, Nox, VOC, CO measured to see if within permit status

18-0120A3 Baghouse # 3 & #5 10/11/2005 10/9/2006 Controlled X CO, NOx, SO2, VOC Compliance PM, SO2, Nox, VOC, CO measured to see if within permit status 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-byrun 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.

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

**FORM G - MONITORING AND OTHER COSTS**

**Facility ID** 18-0120

**Unit Costs for January 2008**

Parameter Cost Electricity cost, $/kwh n/a Reagent: n/a Reagent Cost, $/ton n/a Waste Reagent disposal cost, $/ton or $/yearn/a Water treatment costs, $/gal n/a

Activity Required by Activity Estimated Hours Frequency Staff Level Develop a start-up, shutdown, and malfunction plan Develop plan and educate staff 1 hour every 6 months maintenance manager Develop and implement an operating, maintenance, and monitoring plan Develop plan and educate staff 2 hours to do rounds scheduled

every shift maintenance manager

Bag replacement Replace single bag 20 min once every 6 months maintenance engineer Bag replacement Replace all bags 4-5 3 years Maintenance

Maintain free-flowing lime (Describe action in next box and then add estimated hours, frequency, and staff level) will physically measure lime once a day to comply with regs inspected 6 times a day visually and continuously monitored by pressure drop 1 1/2twice a day of continuously monitored manager, 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 physically measured by environmental coordinator and adjust as needed depending on humidity twice a day continuously monitored by pressure drops and visually by maint. manager-environmental coordinator and maintenance

Control Device:
Compliance demonstration Activity (describe and estimate hours, frequency, and staff level)n/a
Compliance demonstration Activity (describe and estimate hours, frequency, and staff level)n/a
Compliance demonstration Activity (describe and estimate hours, frequency, and staff level)n/a
Daily Maintenance (list activity(ies) in next column) Performed as needed - check status monitored 6 times a day maintenance - manager Weekly Maintenance (list activity(ies) in next column) performed as needed - monitored maintenance - manager Monthly Maintenance (list activity(ies) in next column) performed as needed - monitored maintenance - manager Semi-Annual Maintenance (list activity(ies) in next column) shutdown twice a year and pull main twice a year maintenance - manager Yearly Maintenance (list activity(ies) in next column) performed as needed - monitored onces a year maintenance - manager
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)

10/12/2005measured actual HCl, HF, SO2 emissionsControlled n/a

10/11/2005measured actual PM concentration

(gr/dscf), PM mass rate limit (lbs/hr), SO2 mass rate (lbs/hr) Controlled n/a

10/10/2005measured actual SO2 mass emission rate

(lb/hr), SO2 emissions factor (lbs/ton greenware) Controlled n/a

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

09000064819353ef 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 18-0120 n/a n/a n/a n/a n/a n/a n/a

09000064819353ef 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 n/a 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. none 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. included

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

# These are the picklists for the other tables - this sheet will be hidden when the survey is sent to facilities.

CORPSIZEHAPSIZE KILNTYPE FUEL SECFUELKILNCONTROL REASON GZCONTROL YESNO TESTS STAFF RECIR DLA1 DLA2 WTRCRT

0-99 Major source Tunnel kiln Natural gas None Dry Limestone Adsorber (DLA) Comply with

MACT Water curtain Yes UncontrolledOperator RecirculatedPressure Drop Daily climb to

hopper Baffles

100-249Area Source (synthetic) Roller kiln Sawdust Natural gas Dry Injection/Fabric

Filter (DIFF) Become

Synthetic Minor Wet scrubber No Controlled MaintenanceOne pass AlternativeRemote visual insp. Mist eliminator

250-499Not sure Shuttle kiln Coal SawdustDry Lime Scrubber (DLS) SO2 control Fabric filter Both Engineer Fill/discharge records Both

>500 Kiln-inactive Fuel Oil Coal Wet Scrubber Particulate/ opac. controlOther Manager Other Neither
Other periodic kilnLandfill/Biogas Fuel Oil Fabric Filter/ Baghouse only Other

Other PropaneLime system (unsure if DIFF or DLS)
Landfilll/ Biogas Spray Dryer/

Electrostatic Precipitator Other Other