INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY

FORM A - GENERAL INFORMATION

Parent Company Information

Parent Company Kohler Co.

Street Address - Line 1 444 Highland Drive

Street Address - Line 2 Mail Stop 009

City Kohler

State WI

Zip code 53044

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 006073225

Facility Information

Facility 1 Facility 2 Facility 3 Facility 4

Facility ID KOHL-WI KOHL-SC KOHL-TX

Facility Name Kohler Co. Kohler Co. Kohler Co.

Address 1 444 Highland Drive 4000 South Pine Street 4601 HWY 377 South

Address 2

City Kohler Spartanburg Brownwood

County Sheboygan Spartanburg Brown

State WI SC TX

Zip code 53044 29302 76801

Mailing Address (if different) - Line 1 P.O. Box 1987

Mailing Address (if different) - Line 2

City Spartanburg

State SC

Zip code 29304

Number of employees at facility 250-499 >500 >500

What is your size classification for HAP emissions? Major source Major source Major source

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

Facility's primary NAICS or SIC code 3261 3261 3261

Total Number of Periodic Kilns at this Facility 6 3 7

Total Number of Tunnel Kilns at this Facility 5 6 4

Contact Person for this ICR Mike Cassidy Mike Cassidy Mike Cassidy

Contact Phone Number 920-457-4441, x77263 920-457-4441, x77263 920-457-4441, x77263

Contact Email Address mike.cassidy@kohler.com mike.cassidy@kohler.com mike.cassidy@kohler.com

EPA-HQ-OAR-2013-0290-DRAFT-0019

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, 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 applicable

Average / 

Actual 

Capacity 

Utilization (%) 

(a) Primary Fuel

Secondary 

Fuel

Percent Use of 

Secondary Fuel 

(% of operating 

time) Back-up Fuel

KOHL-WI TK-2 Tunnel kiln 1920's 4.0 No first-fire sanitaryware 5568 Deleted 0.6 Deleted Natural gas None N/A Propane

KOHL-WI TK-3 Kiln-inactive 1920's 4.0 No first-fire sanitaryware 0 Deleted 0.6 Deleted Natural gas None N/A Propane

KOHL-WI TK-4 Kiln-inactive 1920's 4.0 No first-fire sanitaryware 0 Deleted 0.7 Deleted Natural gas None N/A Propane

KOHL-WI TK-5 Tunnel kiln 1920's 4.0 No re-fire sanitaryware 8760 Deleted 0.7 Deleted Natural gas None N/A Propane

KOHL-WI TK-6 Tunnel kiln 1920's 4.0 No re-fire sanitaryware 8760 Deleted 0.6 Deleted Natural gas None N/A Propane

KOHL-WI TK-7 Tunnel kiln 1920's 4.0 No first-fire sanitaryware 8760 Deleted 0.25 Deleted Natural gas None N/A Propane

KOHL-WI SK-10 Shuttle kiln 0 1959 3.0 No re-fire sanitaryware 8760 Deleted 0.2 Deleted Natural gas None N/A Propane

KOHL-WI SK-11 Shuttle kiln 0 2003 4.5 No first-fire sanitaryware 8760 Deleted 0.75 Deleted Natural gas None N/A Propane

KOHL-WI SK-11 Shuttle kiln 0 2003 4.5 No re-fire sanitaryware N/A Deleted 0.75 Deleted Natural gas None N/A Propane

KOHL-WI SK-12 Shuttle kiln 0 2003 4.5 No first-fire sanitaryware 8760 Deleted 0.75 Deleted Natural gas None N/A Propane

KOHL-WI SK-12 Shuttle kiln 0 2003 4.5 No re-fire sanitaryware N/A Deleted 0.75 Deleted Natural gas None N/A Propane

KOHL-WI SK-16 Shuttle kiln 0 2006 5.0 No first-fire sanitaryware 8760 Deleted 1.0 Deleted Natural gas None N/A Propane

KOHL-WI SK-17 Shuttle kiln 0 2006 5.0 No first-fire sanitaryware 8760 Deleted 1.0 Deleted Natural gas None N/A Propane

KOHL-WI SK-18 Shuttle kiln 0 2006 5.0 No first-fire sanitaryware 8760 Deleted 1.0 Deleted Natural gas None N/A Propane

KOHL-SC TK-1 Tunnel kiln 1959 3.0 No re-fire sanitaryware 2190 Deleted 1.2 Deleted Natural gas None N/A Propane

KOHL-SC TK-2 Tunnel kiln 1959 3.0 No first-fire sanitaryware 8760 Deleted 1.4 Deleted Natural gas None N/A Propane

KOHL-SC TK-3 Kiln-inactive 1959 3.0 No first-fire sanitaryware 8760 Deleted 1.4 Deleted Natural gas None N/A Propane

KOHL-SC TK-4 Tunnel kiln 1959 3.0 No re-fire sanitaryware 5840 Deleted 1.2 Deleted Natural gas None N/A Propane

KOHL-SC SK-6 Shuttle kiln 0 1989 4.5 No re-fire sanitaryware 8760 Deleted Deleted Natural gas None N/A Propane

KOHL-SC SK-7 Shuttle kiln 0 1990 4.5 No re-fire sanitaryware 8760 Deleted Deleted Natural gas None N/A Propane

KOHL-SC TK-8 Tunnel kiln 1994 3.0 No first-fire sanitaryware 8760 Deleted 3.35 Deleted Natural gas None N/A Propane

KOHL-SC SK-9 Shuttle kiln 0 1999 2.0 No re-fire sanitaryware 8760 Deleted Deleted Natural gas None N/A Propane

KOHL-SC TK-10 Tunnel kiln 2005 3.0 Yes first-fire sanitaryware 8760 Deleted 0.75 Deleted Natural gas None N/A Propane

KOHL-TX TK-1 Tunnel kiln 1974 4.0 No re-fire sanitaryware 8760 Deleted 0.83 Deleted Natural gas None N/A None

KOHL-TX TK-2 Tunnel kiln 1974 4.0 No re-fire sanitaryware 8760 Deleted 0.83 Deleted Natural gas None N/A None

KOHL-TX SK-3 Shuttle kiln 0 1976 2.0 No re-fire sanitaryware 0 Deleted 0.27 Deleted Natural gas None N/A None

KOHL-TX SK-4 Shuttle kiln 0 1976 2.0 No re-fire sanitaryware 0 Deleted 0.27 Deleted Natural gas None N/A None

KOHL-TX SK-5 Shuttle kiln 0 1981 2.0 No re-fire sanitaryware 4212 Deleted 0.34 Deleted Natural gas None N/A None

KOHL-TX TK-6 Shuttle kiln 1982 4.0 No first-fire sanitaryware 8760 Deleted 2.2 Deleted Natural gas None N/A None

KOHL-TX SK-7 Shuttle kiln 0 1982 3.3 No re-fire sanitaryware 6962 Deleted 0.59 Deleted Natural gas None N/A None

KOHL-TX SK-8 Shuttle kiln 0 1982 3.3 No re-fire sanitaryware 6962 Deleted 0.59 Deleted Natural gas None N/A None

KOHL-TX SK-9 Shuttle kiln 0 1987 8.0 No re-fire sanitaryware 6962 Deleted 0.46 Deleted Natural gas None N/A None

KOHL-TX SK-11 Shuttle kiln 0 1995 4.0 No re-fire sanitaryware 7304 Deleted 0.08 Deleted Natural gas None N/A None

KOHL-TX TK-12 Tunnel kiln 1995 4.0 No first-fire sanitaryware 8760 Deleted 4.9 Deleted Natural gas None N/A None

 = CBI (confidential business information)

FUEL USAGE

(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

EPA-HQ-OAR-2013-0290-DRAFT-0019

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, RK-1, 2, 

etc for roller, and 

PK-1, 2, etc for 

periodic]

KOHL-WI TK-2

KOHL-WI TK-3

KOHL-WI TK-4

KOHL-WI TK-5

KOHL-WI TK-6

KOHL-WI TK-7

KOHL-WI SK-10

KOHL-WI SK-11

KOHL-WI SK-11

KOHL-WI SK-12

KOHL-WI SK-12

KOHL-WI SK-16

KOHL-WI SK-17

KOHL-WI SK-18

KOHL-SC TK-1

KOHL-SC TK-2

KOHL-SC TK-3

KOHL-SC TK-4

KOHL-SC SK-6

KOHL-SC SK-7

KOHL-SC TK-8

KOHL-SC SK-9

KOHL-SC TK-10

KOHL-TX TK-1

KOHL-TX TK-2

KOHL-TX SK-3

KOHL-TX SK-4

KOHL-TX SK-5

KOHL-TX TK-6

KOHL-TX SK-7

KOHL-TX SK-8

KOHL-TX SK-9

KOHL-TX SK-11

KOHL-TX TK-12

(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

Reason(s) back-up 

would be used 

(e.g., NG 

curtailment)

Total time 

back-up 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)

NG curtailment 0

NG curtailment 0

NG curtailment 0

NG curtailment 0

NG curtailment 0

NG curtailment 0

NG curtailment 0 Deleted 38 107 8 8

NG curtailment 0 Deleted 22 275 8 8

NG curtailment 0 Deleted 22 N/A 8 8

NG curtailment 0 Deleted 22 274 8 8

NG curtailment 0 Deleted 22 N/A 8 8

NG curtailment 0 Deleted 22 271 8 8

NG curtailment 0 Deleted 22 248 8 8

NG curtailment 0 Deleted 22 242 8 8

NG curtailment 0

NG curtailment 0

NG curtailment 0

NG curtailment 0

NG curtailment 0 Deleted 38 226 6 6

NG curtailment 0 Deleted 38 211 6 6

NG curtailment 0

NG curtailment 0 Deleted 28 197 6 6

NG curtailment 0

N/A 0

N/A 0

N/A 0 Deleted 40 0 0 0

N/A 0 Deleted 40 0 0 0

N/A 0 Deleted 40 105 3.0 3.0

N/A 0

N/A 0 Deleted 34 205 3.0 3.0

N/A 0 Deleted 34 205 3.0 3.0

N/A 0 Deleted 44 158 3.0 3.0

N/A 0 Deleted 44 166 3.0 3.0

N/A 0

EPA-HQ-OAR-2013-0290-DRAFT-0019

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 Booth 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 Booth

Is this Glaze Booth 

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)

KOHL-WI P11 - Q02/Q03 N/A 1966 7032 Yes

KOHL-WI P12 - Q35 N/A 1969 7656 Yes

KOHL-WI P13 - Q07 N/A 1966 2352 Yes

KOHL-WI P14 - Q08 N/A 1966 3480 Yes

KOHL-WI P15 - Q09 N/A 1966 8208 Yes

KOHL-WI P16A - Q04 N/A 2005 3516 Yes

KOHL-WI P16B - Q05 N/A 2005 3516 Yes

KOHL-WI P17 - Q01 N/A 1954 6240 Yes

KOHL-WI P18 - Q24 N/A 2002 5904 Yes

KOHL-WI P19 - Q13 N/A 1954 1760 Yes

KOHL-WI P20A - R01 N/A 1981 360 Yes

KOHL-WI P20B - R03 N/A 1981 5620 Yes

KOHL-WI P20C - R04 N/A 1981 3372 Yes

KOHL-WI P21 - R02 N/A 1981 6744 Yes

KOHL-WI P22 - R05 N/A 1954 6744 Yes

KOHL-WI IEU - Q10 N/A 1954 2000 Yes

KOHL-WI IEU - Q12 N/A 2005 8400 Yes

KOHL-SC 05 - OTM (1F) N/A 1965 8280 Yes

KOHL-SC 06 - LBM (1F) N/A 1969 2448 Yes

KOHL-SC 07 - BBM (1F) N/A 1988 8568 Yes

KOHL-SC 08 - Robot 2 (1F) N/A 2001 8568 Yes

KOHL-SC 09 - Robot 3 (1F) N/A 2003 8568 Yes

KOHL-SC 10 - Hand 3 (1F) N/A 1988 8568 Yes

KOHL-SC 11 - Hand 2 (1F) N/A 1988 0 Yes

KOHL-SC 12 - NTM (1F) N/A 1992 8568 Yes

KOHL-SC 13 - Refire (2F) N/A 1958 8568 Yes

KOHL-SC 37 - Robot 4 (1F) N/A 2004 0 Yes

KOHL-SC 39 - Respray 1 (2F) N/A 2005 8568 Yes

KOHL-SC 39 - Respray 2 (2F) N/A 2005 8568 Yes

KOHL-SC 39 - Respray 3 (2F) N/A 2005 8568 Yes

KOHL-TX EPN013 - Manual SB N/A 1976 4284 Yes

KOHL-TX EPN014 - Bowl SM 1 N/A 1976 8568 Yes

KOHL-TX EPN015 - Bowl SM 2 N/A 1976 8568 Yes

KOHL-TX EPN074 - Lab SB N/A 1977 510 Yes

KOHL-TX EPN103 - 1P N/A 1982 4284 Yes

KOHL-TX EPN104 - 1P N/A 1982 4284 Yes

KOHL-TX EPN105 - 1P N/A 1982 4284 Yes

KOHL-TX EPN106 - 1P N/A 1982 4284 Yes

KOHL-TX EPN163 - Brilliance N/A 1987 114.5 Yes

KOHL-TX

EPN165A - 

Wellworth Rework N/A 1988 4200 Yes

KOHL-TX

EPN165B - 

Wellworth Rework N/A 1988 4200 Yes

KOHL-TX

EPN165C - 

Wellworth Rework N/A 1988 4200 Yes

KOHL-TX

EPN165D - 

Wellworth Rework N/A 1988 4200 Yes

KOHL-TX

EPN165E - 

Wellworth Rework N/A 1988 0 Yes

KOHL-TX EPN166 - Op 5 N/A 1988 4284 Yes

KOHL-TX EPN208 - 1P Rework N/A 1996 4200 Yes

KOHL-TX EPN209 - 1P Rework N/A 1996 4200 Yes

KOHL-TX EPN210 - 1P Rework N/A 1996 4200 Yes

KOHL-TX EPN211 - 1P Rework N/A 1996 4200 Yes

KOHL-TX EPN212 - 1P Rework N/A 1996 4200 Yes

KOHL-TX EPN213 - 1P Rework N/A 1996 4200 Yes

KOHL-TX

EPN243 - WW 

Rework N/A 1999 4200 Yes

KOHL-TX

EPN244 - WW 

Rework N/A 1999 4200 Yes

KOHL-TX

EPN245 - WW 

Rework N/A 1999 4200 Yes

KOHL-TX

EPN246 - WW 

Rework N/A 1999 4200 Yes

KOHL-TX EPN251 - Robot N/A 2002 4284 Yes

 = CBI (confidential business information )

FACILITY and GLAZE BOOTH 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

Deleted as CBI

Deleted as CBI

Deleted as CBI

EPA-HQ-OAR-2013-0290-DRAFT-0019

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

KOHL-SC TK10 3.0 scrubber Wet Scrubber Comply with MACT 1 2005

FACILITY and KILN IDs

EPA-HQ-OAR-2013-0290-DRAFT-0019

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]

KOHL-SC TK10

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)

orifice plate N/A

EPA-HQ-OAR-2013-0290-DRAFT-0019

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]

KOHL-SC TK10

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

4 and above 5.6 and above NaOH 275.0gal 4 fl. oz./hr

EPA-HQ-OAR-2013-0290-DRAFT-0019

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

Facility ID

Glaze Booth 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 filter 

surface area (ft2)

filter- material of 

construction

Avg Life of filters 

(yrs)

Cleaning 

method

Type of 

scrubber (e.g., 

venturi)

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

KOHL-WI P11 - Q02/Q03 Water curtain

Particulate/ 

opac. control 1 1966 75 10 ft. Neither

water flow 

adequacy 1 / shift

KOHL-WI P12 - Q35 Water curtain

Particulate/ 

opac. control 1 1969 75 9ft. 4 in. Neither

water flow 

adequacy 1 / shift

KOHL-WI P13 - Q07 Water curtain

Particulate/ 

opac. control 1 1966 75 5 ft. Neither

water flow 

adequacy 1 / shift

KOHL-WI P14 - Q08 Water curtain

Particulate/ 

opac. control 1 1966 75 5 ft. 1 in. Neither

water flow 

adequacy 1 / shift

KOHL-WI P15 - Q09 Water curtain

Particulate/ 

opac. control 1 1966 75 5 ft. 3 in. Neither

water flow 

adequacy 1 / shift

KOHL-WI P16A - Q04 Wet scrubber

Particulate/ 

opac. control 2 1980 multi-vane 65 1 - 6 Baffles pressure drop 1 / shift

KOHL-WI P16B - Q05 Wet scrubber

Particulate/ 

opac. control 2 1980 multi-vane 65 1 - 6 Baffles pressure drop 1 / shift

KOHL-WI P17 - Q01 Water curtain

Particulate/ 

opac. control 1 1954 75 5 ft. 1 in. Neither

water flow 

adequacy 1 / shift

KOHL-WI P18 - Q24 Water curtain

Particulate/ 

opac. control 1 2002 75 9 ft. 4 in. Baffles

water flow 

adequacy 1 / shift

KOHL-WI P19 - Q13 Water curtain

Particulate/ 

opac. control 1 1954 75 5 ft. 2 in. Neither

water flow 

adequacy 1 / shift

KOHL-WI P20A - R01 Other

Particulate/ 

opac. control 1 1981 11

Craft paper 

front/polyester 

backing 1 week Replacement Neither

filter media 

installation 1 / shift

KOHL-WI P20B - R03 Other

Particulate/ 

opac. control 1 1981 6

Craft paper 

front/polyester 

backing 1 week Replacement Neither

filter media 

installation 1 / shift

KOHL-WI P20C - R04 Other

Particulate/ 

opac. control 1 1981 6

Craft paper 

front/polyester 

backing 1 week Replacement Neither

filter media 

installation 1 / shift

KOHL-WI P21 - R02 Other

Particulate/ 

opac. control 1 1981 22

Craft paper 

front/polyester 

backing 1 week Replacement Neither

filter media 

installation 1 / shift

KOHL-WI P22 - R05 Water curtain

Particulate/ 

opac. control 1 1954 75 5 ft. Neither

water flow 

adequacy 1 / shift

KOHL-WI IEU - Q10 Other

Particulate/ 

opac. control 1 1966 30 cotton fiber 1 Replacement Neither

filter media 

installation 1 / shift

KOHL-WI IEU - Q12 Other

Particulate/ 

opac. control 1 2005 60

sintered 

composite 2 Replacement Baffles

filter media 

installation 1 / shift

KOHL-SC 05 - OTM W02A Water curtain

Particulate/ 

opac. control 1 1965 45 10 Baffles

water flow 

adequacy 1/shift

KOHL-SC 06 - LBM W02B Water curtain

Particulate/ 

opac. control 1 1969 45 10 Baffles

water flow 

adequacy 1/shift

KOHL-SC 07 - BBM W02C Water curtain

Particulate/ 

opac. control 1 1988 45 14 Baffles

water flow 

adequacy 1/shift

KOHL-SC 08 - Robot 2 W02D Water curtain

Particulate/ 

opac. control 1 2001 45 10 Baffles

water flow 

adequacy 1/shift

KOHL-SC 09 - Robot 3 W02E Water curtain

Particulate/ 

opac. control 1 2003 45 10 Baffles

water flow 

adequacy 1/shift

KOHL-SC 10 - Hand 3 W02F Water curtain

Particulate/ 

opac. control 1 1988 45 10 Baffles

water flow 

adequacy 1/shift

KOHL-SC 11 - Hand 2 W02G Water curtain

Particulate/ 

opac. control 1 1988 45 10 Baffles

water flow 

adequacy 1/shift

KOHL-SC 12 - NTM W02H Water curtain

Particulate/ 

opac. control 1 1992 45 10 Baffles

water flow 

adequacy 1/shift

KOHL-SC 13 - Refire W02X Water curtain

Particulate/ 

opac. control 1 1958 45 10 Neither

water flow 

adequacy 1/shift

KOHL-SC 37 - Robot 4 W04X Water curtain

Particulate/ 

opac. control 1 2004 45 10 Baffles

water flow 

adequacy 1/shift

KOHL-SC 39 - Respray 1 Filter Other

Particulate/ 

opac. control 1 2005 6.25 polypropylene 1 week REPLACE NA NA Neither pressure drop 1/shift

KOHL-SC 39 - Respray 2 Filter Other

Particulate/ 

opac. control 1 2005 6.25 polypropylene 1 week REPLACE NA NA Neither pressure drop 1/shift

KOHL-SC 39 - Respray 3 Filter Other

Particulate/ 

opac. control 1 2005 6.25 polypropylene 1 week REPLACE NA NA Neither pressure drop 1/shift

KOHL-TX EPN013 - Manual SB C013 Water curtain

Particulate/ 

opac. control 1 1976 0 - pumpless 14' Baffles

water flow 

adequacy 1/shift

KOHL-TX EPN014 - Bowl SM 1 C014 Water curtain

Particulate/ 

opac. control 1 1976 0 - pumpless 16' Baffles

water flow 

adequacy 1/shift

KOHL-TX EPN015 - Bowl SM 2 C015 Water curtain

Particulate/ 

opac. control 1 1976 0 - pumpless 21' Baffles

water flow 

adequacy 1/shift

KOHL-TX EPN074 - Lab SB C074 Other

Particulate/ 

opac. control 1 1977 Baffles

installation and 

cleaning 1/day

KOHL-TX EPN103 - 1P C103 Water curtain

Particulate/ 

opac. control 1 1982 0 - pumpless 10' Baffles

water flow 

adequacy 1/shift

KOHL-TX EPN104 - 1P C104 Water curtain

Particulate/ 

opac. control 1 1982 0 - pumpless 10' Baffles

water flow 

adequacy 1/shift

KOHL-TX EPN105 - 1P C105 Water curtain

Particulate/ 

opac. control 1 1982 0 - pumpless 10' Baffles

water flow 

adequacy 1/shift

KOHL-TX EPN106 - 1P C106 Water curtain

Particulate/ 

opac. control 1 1982 0 - pumpless 10' Baffles

water flow 

adequacy 1/shift

KOHL-TX EPN163 - Brilliance C163 Other

Particulate/ 

opac. control 1 1987 11.2

metal mesh filter 

media 20

water 

washdown Baffles

installation and 

cleaning 1/day

KOHL-TX

EPN165A - 

Wellworth Rework C165A Other

Particulate/ 

opac. control 1 1988 11.2

metal mesh filter 

media 20

water 

washdown Baffles

installation and 

cleaning 1/day

KOHL-TX

EPN165B - 

Wellworth Rework C165B Other

Particulate/ 

opac. control 1 1988 11.2

metal mesh filter 

media 20

water 

washdown Baffles

installation and 

cleaning 1/day

KOHL-TX

EPN165C - 

Wellworth Rework C165C Other

Particulate/ 

opac. control 1 1988 11.2

metal mesh filter 

media 20

water 

washdown Baffles

installation and 

cleaning 1/day

KOHL-TX

EPN165D - 

Wellworth Rework C165D Other

Particulate/ 

opac. control 1 1988 11.2

metal mesh filter 

media 20

water 

washdown Baffles

installation and 

cleaning 1/day

KOHL-TX

EPN165E - 

Wellworth Rework C165E Other

Particulate/ 

opac. control 1 1988 11.2

metal mesh filter 

media 20

water 

washdown Baffles

installation and 

cleaning 1/day

KOHL-TX EPN166 - Op 5 C166 Water curtain

Particulate/ 

opac. control 1 1988 0 - pumpless 6' Baffles

water flow 

adequacy 1/shift

KOHL-TX EPN208 - 1P Rework C208 Other

Particulate/ 

opac. control 1 1996 11.2

metal mesh filter 

media 20

water 

washdown Baffles

installation and 

cleaning 1/day

KOHL-TX EPN209 - 1P Rework C209 Other

Particulate/ 

opac. control 1 1996 11.2

metal mesh filter 

media 20

water 

washdown Baffles

installation and 

cleaning 1/day

KOHL-TX EPN210 - 1P Rework C210 Other

Particulate/ 

opac. control 1 1996 11.2

metal mesh filter 

media 20

water 

washdown Baffles

installation and 

cleaning 1/day

KOHL-TX EPN211 - 1P Rework C211 Other

Particulate/ 

opac. control 1 1996 11.2

metal mesh filter 

media 20

water 

washdown Baffles

installation and 

cleaning 1/day

KOHL-TX EPN212 - 1P Rework C212 Other

Particulate/ 

opac. control 1 1996 11.2

metal mesh filter 

media 20

water 

washdown Baffles

installation and 

cleaning 1/day

KOHL-TX EPN213 - 1P Rework C213 Other

Particulate/ 

opac. control 1 1996 11.2

metal mesh filter 

media 20

water 

washdown Baffles

installation and 

cleaning 1/day

KOHL-TX

EPN243 - WW 

Rework C243 Other

Particulate/ 

opac. control 1 1999 11.2

metal mesh filter 

media 20

water 

washdown Baffles

installation and 

cleaning 1/day

KOHL-TX

EPN244 - WW 

Rework C244 Other

Particulate/ 

opac. control 1 1999 11.2

metal mesh filter 

media 20

water 

washdown Baffles

installation and 

cleaning 1/day

KOHL-TX

EPN245 - WW 

Rework C245 Other

Particulate/ 

opac. control 1 1999 11.2

metal mesh filter 

media 20

water 

washdown Baffles

installation and 

cleaning 1/day

KOHL-TX

EPN246 - WW 

Rework C246 Other

Particulate/ 

opac. control 1 1999 11.2

metal mesh filter 

media 20

water 

washdown Baffles

installation and 

cleaning 1/day

KOHL-TX EPN251 - Robot C251 Water curtain

Particulate/ 

opac. control 1 2002 70 12' Baffles

water flow 

adequacy 1/shift

EPA-HQ-OAR-2013-0290-DRAFT-0019

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

KOHL-SC scrubber

Kiln 10 / 

Unit ID 38 2/7/2007 2/19/2007 Controlled X X X

Initial Performance Test under 

Clay MACT (before it was 

vacated)

1) pressure drop across 

scrubber; 2) pH of scrubber 

liquid

Stack test report submitted to EPA in 3/12/2008 email from Mike Cassidy (Kohler Co.) to Jeff Telander

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. 

EPA-HQ-OAR-2013-0290-DRAFT-0019

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

FORM G - MONITORING AND OTHER COSTS

Facility ID KOHL-WI

This facility treats wastewater from spray booths on-site and recycles the treated water for clean-up and spray booth 

water curtains. The cost below pertains to water treatment only.

Unit Costs for January 2008

Parameter Cost

Electricity cost, $/kwh $0.06

Reagent: Water $1.40/1,000 gallons

Reagent Cost, $/ton --

Waste Reagent disposal cost, $/ton or $/year See below

Water treatment costs, $/gal 0.02

Activity Required by Activity Estimated Hours Frequency Staff Level

Develop a start-up, shutdown, and malfunction 

plan Develop plan and educate staff 

Develop and implement an operating, 

maintenance, and monitoring plan Develop plan and educate staff 

Bag replacement Replace single bag

Bag replacement Replace all bags

Maintain free-flowing lime (Describe action in 

next box and then add estimated hours, 

frequency, and staff level)

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 informati

Control Device: 

Compliance demonstration Activity (describe 

and estimate hours, frequency, and staff level)

Compliance demonstration Activity (describe 

and estimate hours, frequency, and staff level)

Compliance demonstration Activity (describe 

and estimate hours, frequency, and staff level)

Daily Maintenance (list activity(ies) in next 

column)

visual compliance check on each booth 

and recordkeeping (per booth) 1/2 hour week Operator

Weekly Maintenance (list activity(ies) in next 

column) spray booth clean-up (per booth) 2 hours week Operator

Monthly Maintenance (list activity(ies) in next 

column)

scheduled maintenance on water walls, 

dry filters, fans (per booth) 1 hour month Maintenance

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)

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)

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

EPA-HQ-OAR-2013-0290-DRAFT-0019

FORM G - WI Monit-Other Costs 12/1/2014
INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY

FORM G - MONITORING AND OTHER COSTS

Facility ID KOHL-SC

Information is relevent to the Kiln 10 Orifice scrubber only, and does not include any information for spray booths or other devices.

This facility treats wastewater from spray booths on-site and recycles the treated water for clean-up and spray booth water curtains.

Unit Costs for January 2008

Parameter Cost

Electricity cost, $/kwh 0.048

Reagent: 25% NaOH

Reagent Cost, $/ton $250

Waste Reagent disposal cost, $/ton or $/year N/A

Water treatment costs, $/gal $0.02

Activity Required by Activity Estimated Hours Frequency Staff Level

Develop a start-up, shutdown, and malfunction 

plan Develop plan and educate staff 200 initial Engineer

Develop and implement an operating, 

maintenance, and monitoring plan Develop plan and educate staff 150 initial Engineer

Bag replacement Replace single bag

Bag replacement Replace all bags

Maintain free-flowing lime (Describe action in 

next box and then add estimated hours, 

frequency, and staff level)

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 informati

Control Device: 

Compliance demonstration Activity (describe 

and estimate hours, frequency, and staff level) pH probe calibration 1 hour weekly Maintenance

Compliance demonstration Activity (describe 

and estimate hours, frequency, and staff level)

scheduled maintenance for pressure drop 

instrumentation and sump liquid level 

controller 1 hour monthly Maintenance

Compliance demonstration Activity (describe 

and estimate hours, frequency, and staff level)

scheduled maintenance for chemical feed 

pump and controller 1 hour monthly Maintenance

Compliance demonstration Activity (describe 

and estimate hours, frequency, and staff level)

scheduled maintenance for sump liquid 

bleed off system 1 hour monthly Maintenance

Compliance demonstration Activity (describe 

and estimate hours, frequency, and staff level)

scheduled maintenance for pH sensor and 

controller 1 hour monthly Maintenance

Compliance demonstration Activity (describe 

and estimate hours, frequency, and staff level)

scheduled maintenance for make-up 

water flowmeter and controller 1 hour monthly Maintenance

Compliance demonstration Activity (describe 

and estimate hours, frequency, and staff level)

review operating parameter monitoring 

reports 1 hour weekly Engineer

Compliance demonstration Activity (describe 

and estimate hours, frequency, and staff level)

documentation (for maintenance 

activities, scrubber upsets, etc.) 2 hours monthly Engineer

Daily Maintenance (list activity(ies) in next 

column) visual equipment check 1/4 hour daily Engineer

Weekly Maintenance (list activity(ies) in next 

column)

Monthly Maintenance (list activity(ies) in next 

column) replace water supply filter 1 hour monthly Maintenance

Monthly Maintenance (list activity(ies) in next 

column)

scheduled maintenance for exhaust 

system fan 1hour monthly Maintenance

Semi-Annual Maintenance (list activity(ies) in 

next column)

Yearly Maintenance (list activity(ies) in next 

column)

clean out scrubber, exhaust fan, 

associated equipment 16 hours yearly Maintenance

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)

2007

USEPA Reference Methods 1-5, 

Reference Method 26A Controlled $4,000 $2,500

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

EPA-HQ-OAR-2013-0290-DRAFT-0019

FORM G - SC Monit-Other Costs 12/1/2014
INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY

FORM G - MONITORING AND OTHER COSTS

Facility ID KOHL-TX

Unit Costs for January 2008

Parameter Cost

Electricity cost, $/kwh 0.09

Reagent: $1.40/1,000 gallons

Reagent Cost, $/ton $0.00

Waste Reagent disposal cost, $/ton or $/year

Water treatment costs, $/gal $0.02

Water from water curtain spray booths is treated on-site and recycled back to the booths.

Estimated hours below is per booth, not total for all booths.

Activity Required by Activity Estimated Hours Frequency Staff Level

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

Develop and implement an operating, maintenance, 

and monitoring plan Develop plan and educate staff 

Bag replacement Replace single bag

Bag replacement Replace all bags

Maintain free-flowing lime (Describe action in next 

box and then add estimated hours, frequency, and 

staff level)

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 informati

Control Device: Water Curtain 

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)

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

check motor mounting, belts and any 

unusual noises or vibration. 0.25 weekly Maintenance

Weekly Maintenance (list activity(ies) in next column) Cleaning 2.5 weekly Operator

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)

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)

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

EPA-HQ-OAR-2013-0290-DRAFT-0019

FORM G - TX 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

KOHL-SC Sanitaryware Deleted Deleted Deleted Deleted Deleted

KOHL-WI Sanitaryware Deleted Deleted Deleted Deleted Deleted

KOHL-TX Sanitaryware Deleted Deleted Deleted Deleted Deleted

 = CBI (confidential business information )

EPA-HQ-OAR-2013-0290-DRAFT-0019

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

KOHL-SC: For Kiln 10 orifice scrubber only. The total purchased equipment cost (ductwork, 

scrubber, pumps, sensors, etc.) for the control device was $168,275. The direct installation 

cost, including site prep and instrumentation software programing, was $58,900, so total direct 

capital cost was $227,175. Assuming no indirect capital costs, total capital investment was 

$227,175. The quoted maximum design greenware throughput of the kiln is 4,000 lbs/hr ( 

2T/hr). HF and HCl emissions at this design rate for 8760 hours/yr would total 1.5 tons/year; 

equivalent to a cost effectiveness rate of more than $150,000 TCI/ton HAP reduced. The 

quoted throughput design rate for the kiln has never been achieved. The kiln processed 

approximately 1,500 lbs greenware/hour during the IPT, but normal operation has never 

exceeded 1,000 lbs ware/hour. At this throughput rate, the cost effectiveness of the control 

device is over $600,000 TCI/ton HAP reduced. 

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.) Attached

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

information regarding technological and/or 

economic limitations to testing those kilns?

We have no specific information, but we know of two important considerations: 1) Most 

periodic kilns at Kohler Co. sanitaryware facilities are used for refire. HAP emissions (HF, HCl) 

occur during first fire of greenware, during the vitrification process, and are insignificant during 

refiring. HF and HCl emissions are likely below the reference method detection limits for refire 

kilns. There is no justification to require emissions testing from any refire kilns, whether 

periodic or continuous (tunnel kilns). 2) Since periodic kiln firing cycles start and end at room 

temperature, an emissions test would need to encompass more than just three 1-hour test 

runs. Kohler Co.'s periodic kilns operate on firing cycles anywhere from 22 hours to 44 hours. 

HAP emissions (HF, HCl) are believe to not occur until ware temperature is above 1,0000F. This 

period may be 10-18 hours long over the firing cycle, so for a periodic kiln processing first fire 

ware, more test runs and longer test runs would be needed to capture emissions from the 

cycle, making the emissions test much more expensive than a standard stack test. 

5. Please provide a copy of a process flow diagram 

for your facility, if available. Attached

EPA-HQ-OAR-2013-0290-DRAFT-0019

FORM I - Additional Questions 12/1/2014
Attachment to Form I: CLAY MACT ICR

E (S32)

cases E (S23)

Wet Dry Fabric

E Scrubber E Filter

Molds Slip Glaze Glaze Mixing Dry Glaze Vents indoors

Mill (P23) Batching

Spray Booth Spray Booth

Q02/Q03 (P11) Q35 (P12) P

E P E P 16A E 16B P E E P E P E P E P E P E P E P E P

S18

S11 Water S12 Water S16 Multi-Vane S17 Water S13 Water S14 S15 S19 S20 Dry Fabric S21 S22

 Wall Wall Scrubber Wall Wall Filters

 S27 N.G. S26 N.G. S25 N.G. N.G.

S28 E E E E Not O.K. Repair & Product

Alternative P Alterations

P Stacks P

P P p E S31 E 

S29 E S30 E S24 E

E Inspection P

P P O.K. P

P

O.K.

E = Exhaust Finished 

P = Product Product

AE Spray Booth 

Q13 (P19)

Model / 

Block / Case 

(P32)

Color Spray

Booth Q01 

(P17)

Spot Spray Booths R01 

(P20A), R03 (P20B), R04 

(P20C)

Spot Spray Booth 

R02 (P21)

Respray Booth 

R05 (P22)

N.G. N.G.

Tunnel Kilns 3-

7 (P24)

WHB Combined 

Kiln Exhaust

Shuttle Kiln #11 

(P26)

Shuttle Kiln #12 

(P27)

Dust Collector 

(Baghouse)

Water Wall

N.G.

Product Product

East Spray

Booth Q07 

(P13)

Middle Spray

Booth Q08 

(P14)

West Spray

Booth Q09 

(P15)

WI Vitreous Plant Flow Diagram

Fanuc Robot 

Spray Booth Q24 

(P18)

Ware Grinders 

(P31)

Shuttle Kiln #16 

(P28)

Shuttle Kiln #17 

(P29)

Shuttle Kiln #18 

(P30)

Shuttle Kiln #10 

(P25)

Mold Making Slip Making

Slip Casting

Spray Booths 

Q04 & Q05 

(P16A & B)

Water 

Wall

Water 

Wall

Water 

Wall

Dry 

Fabric 

Filter

Water 

Wall

K:\...\WI Pottery\Air\Permits\Shuttle Kiln 2003\EPA-HQ-OAR-2013-0290-DRAFT-0019,KOHL-WI PFD
Attachment to Form I: Clay MACT ICR

E

 E E E 

Baghouse

E (ID14) E

Molds Slip Glaze Wet Glaze Dry Glaze

Milling

P

Batching

Old Tank SB Little Bowl SB

(ID 05) (ID 06) P

E P E P E P E E P E P E P E P E P E P E P

E

E Water E Water E Water E Water E Water E E E E Dry Fabric E

 Wall Wall Wall Wall Wall Filters

N.G. N.G. N.G. N.G.

E E E E Not O.K. Repair & Product

Alternative P Alterations

P Stacks P

P p E E 

E E E

E Inspection P

P P O.K. P

P

O.K.

E = Exhaust Finished 

P = Product Product

Ware Grinders 

(IDs 25 & 26)

Causstic Wet 

Scrubber

Tunnel Kiln #10 

(ID 38)

Shuttle Kiln #9 (ID 

19)

Shuttle Kiln #6 

(ID 16)

Big Bowl 

Machine (ID 

07)

Spartanburg SC Vitreous Plant Flow Diagram

Robot Spray 

Booth 2 (ID 

08)

Water Wall

Mold Making Slip Making

Slip Casting

Tunnel Kiln #8 

(ID 18)

Dust Collector 

(Baghouse)

Robot Spray 

Booth 4 (ID 

37)

Product Product

Hand Spray 

Booth 3 (ID 

10)

Hand Spray 

Booth 2 (ID 

11)

New Tank 

Machine (ID 

12)

Baghouses 

(IDs 23 & 

24)

Robot Spray 

Booth 3 (ID 

09)

Spot Spray Booths 1, 2, 3 (ID 

39)

Refire Booth 

(ID 13)

N.G. N.G.

Tunnel Kilns 1-

4 (IDs 

01-04)

WHB Combined 

Kiln Exhaust

Shuttle Kiln #7 

(ID 17)

Water 

Wall

Water 

Wall

Water 

Wall

Water 

Wall

K:\...\WI Pottery\Air\Permits\Shuttle Kiln 2003\EPA-HQ-OAR-2013-0290-DRAFT-0019,KOHL-SC PFD 
Attachment to Form I: Clay MACT ICR





Segment Total Time ( min.) Time (min.) Temp (F) Actual ( F ) / min.

0 0 0 70 0.00

1 70 70 250 2.57

2 240 170 800 3.24

3 315 75 1022 2.96

4 409 94 1300 2.96

5 499 90 1800 5.56

6 584 85 2233 5.09

7 611 27 2243 0.37

8 651 40 2252 0.23

9 691 40 2270 0.45

10 721 30 2270 0.00

11 771 50 1600 -13.40

12 948 177 1125 -2.68

13 1043 95 960 -1.74

14 1268 225 280 -3.02

15 1320 52 212 -1.31

1fire K-16,17,18 Firing Profile

0

250

500

750

1000

1250

1500

1750

2000

2250

2500

0 100 200 300 400 500 600

Temperature (oF)

Total Time (min.)

1-Fire Firing Profile

1fire K-16,17,18 Firing Profile
0

200

400

600

800

1000

1200

1400

1600

1800

2000

2200

Te

m

p

erature (F)

Time (Minutes)

Refire Firing Profile Comparison (8-20-08)

30-hrs Refire Firing Profile (4-11-07) 25-hrs Refire Fiiring Profile (1-26-07)

18-hrs Refire Firing Profile Keith Shuttle Kiln-10 Firing Profile
Attachment to Form I: Clay MACT ICR

Shuttle Kilns 6 & 7 have the same curve profiles, so only SK 7 is shown.





Attachment to Form I: Clay MACT ICR

Profile for Shuttle kilns 7 and 8

Profile for Shuttle Kiln 5
Profule for Shuttle Kiln 9

1200

1300

1400

1500

1600

1700

1800

1900

2000

2100

2200

K-9 Curve
Profile for Shuttle Kiln 11

0

100

200

300

400

500

600

700

800

900

1000

1100

1200

1 4 7 10 13 16 19 22 25 28 31 34

100

200

300

400

500

600

700

800

900

1000

1100

1200

1300

1400

1500

1600

1700

1800

1900

2000

2100

2200

1 4 7 10 13 16 19 22 25 28 31 34 37

K-11 Curve


34 37 40 43

Temps.

37 40 43 46

Temps.
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 KILNCONTROL 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 Uncontrolled Operator Recirculated

Pressure 

Drop

Daily climb to 

hopper Baffles

100-249 Area Source (synthetic) Roller kiln Sawdust

Natural 

gas

Dry Injection/Fabric 

Filter (DIFF)

Become 

Synthetic 

Minor Wet scrubber No Controlled Maintenance One pass Alternative

Remote 

visual insp. Mist eliminator

250-499 Not sure Shuttle kiln Coal Sawdust

Dry Lime Scrubber 

(DLS) SO2 control Fabric filter Both Engineer

Fill/discharge 

records Both

>500 Kiln-inactive Fuel Oil Coal Wet Scrubber

Particulate/ 

opac. control Other Manager Other Neither

Other periodic kiln Landfill/Biogas Fuel Oil

Fabric Filter/ 

Baghouse only Other

Other Propane

Lime system 

(unsure if DIFF or 

DLS)

Landfilll/ 

Biogas

Spray Dryer/ 

Electrostatic 

Precipitator

Other Other