# 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.commike.cassidy@kohler.commike.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 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] Reporting

Year (if not 2007)Type of KilnIf periodic, number of identical kilns on this lineYear BuiltStack Diameter (ft) Does this kiln

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

Operating Hours for KilnFull Design

Capacity (tph) Permitted

Capacity (tph) if applicableAverage /

Actual Capacity Utilization (%) **(a)** Primary FuelSecondary 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.** GENERAL INFORMATION FACILITY and KILN IDs 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 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] 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 IDGlaze Booth ID(s)

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

Spray Booths Per LineReporting

Year (if not 2007) Year Built Annual Operating Hours for Glaze BoothIs 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 GlazesHAPs 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 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 deviceYear control device

was installedTotal bag surface

area (ft2

### ) Bag- material of

constructionAvg 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 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] KOHL-SC TK10 FACILITY and KILN IDs DLS or DIFF DLA

Reagent TypeReagent feedrate

(value) Units/ timeTotal 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

frequencyType 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 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] 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 liquidReagents used to

maintain pH in desired rangeTotal 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 above5.6 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 IDGlaze 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 InstalledNumber of spray

booths vented to this control deviceYear

control device was installed Total filter

surface area (ft2)filter- material of

constructionAvg 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 ParameterUnits / 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 IDControl IDKiln/Glaze Line/ Stack IDTest Date Report Date Type of TestUncontrolled (or inlet to control), Controlled, Both HF HCl PMHAP MetalsOther (list below) Other (list

below) Other (list

below)Reasons for Test APCD Parameters Monitored During Test Notes

KOHL-SCscrubberKiln 10 / Unit ID 382/7/2007 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 HoursFrequency 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 weekOperator Weekly Maintenance (list activity(ies) in next column) spray booth clean-up (per booth) 2 hours weekOperator Monthly Maintenance (list activity(ies) in next column) scheduled maintenance on water walls, dry filters, fans (per booth) 1 hour monthMaintenance 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 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)

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 HoursFrequency Staff Level Develop a start-up, shutdown, and malfunction plan Develop plan and educate staff 200 initialEngineer Develop and implement an operating, maintenance, and monitoring plan Develop plan and educate staff 150 initialEngineer 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 HoursFrequency Staff Level Develop a start-up, shutdown, and malfunction planDevelop 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. 0.25weekly Maintenance
Weekly Maintenance (list activity(ies) in next column)Cleaning 2.5weekly 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 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)

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 1,0000

# F. 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 GlazeGlaze Mixing Dry Glaze Vents indoors Mill (P23) Batching

Spray Booth Spray Booth Q02/Q03 (P11) Q35 (P12) P
E P E P 16A E 16BP E E P E P E P E P E P E P E P E P
S18
S11Water S12Water S16Multi-Vane S17Water S13Water S14 S15 S19 S20Dry Fabric S21 S22 Wall Wall Scrubber Wall Wall Filters

S27 N.G. S26 N.G. S25 N.G. N.G. S28E 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 InspectionP
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 GlazeWet 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
EWater EWater E Water EWater EWater E E E EDry 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 InspectionP
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

# Attachm**ent to Form I: Clay MACT ICR** 

## Segment**Total Time ( min.) Time (min.)** **Temp (F) A ctual** **( 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**T e** **m p** **e r** **a t** **u r** **e (** **o F** **)**



## 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**T e** **m p** **e r** **a t** **u r** **e (** **F )** 



# Ti**me (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



# 147101316192225283134

100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200



# 14710131619222528313437 K

-11Curve

# 34374043Temps.



# 37404346Temps.

# 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 GZCONTROLYESNOTESTS STAFF RECIR DLA1 DLA2 WTRCRT
0-99Major source Tunnel kiln Natural gas None Dry Limestone Adsorber (DLA) Comply with

MACT Water curtainYes 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 scrubberNo ControlledMaintenanceOne passAlternativeRemote visual insp.Mist eliminator
250-499Not sure Shuttle kiln Coal SawdustDry Lime Scrubber (DLS) SO2 controlFabric filter Both Engineer Fill/discharge records Both
>500 Kiln-inactive Fuel Oil Coal Wet Scrubber Particulate/ opac. controlOther Manager Other Neither Other periodic kilnLandfill/BiogasFuel OilFabric Filter/ Baghouse only Other

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

Electrostatic Precipitator OtherOther