# STONEPE/\K September9, 2008 MR. JEFFREY TELANDER SECTORPOLICIES AND PROGRAM DIVISION (0243-02) U.S. ENVIRONMENTAL PROTECTION AGENCY OFFICE ofAIR QUALITY PLANNING STANDARDS RESEARCH TRIANGLE PARK,NORTH CAROLINA 27711 RE: STONEPAEKCERAMICS, INC. CERAMICS



# INFORMATION COLLECTION REQUESTfor CLAY CERAMICS MANUFACTURING DearMr. Telander, Please forgive thetardiness ofthis report. Ihad a littletrouble with Form C page 1of 1. Ifthere are any questions about this form, I would really appreciatethe fact that I could call yourofficeto get answers. I have been working with a consultantand much ofthe deta il needed was acquired whenourengineerfrom Italy 

# arrived. I explained our situation in ourprevioustel ephone conversation on08/21/2008 @ 3:01 p.m. Thank you for your patience, cooperation, and help. WARMESTREG



# ul~~ WILLIAM SMITH SAFETYANDENVIRONMENTAL COORDINATOR STONEPEAK CERAMICS CROSSVILLE, TENN. 38555 PHONE: (93 1) 459-2509 FAX : (931) 459-2545

StonePeak Ceramics, Inc. 314 West Superior Chicogo, Illinois 60610 t (

312) 335-0321 

### f (3 12) 335-0533 w stonepeokceromics.com P roduction Facility 238 Porcelain Tile Drive Crossville. Tennessee 38555ENCLOSURE1 INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY FORM A ·GENERAL INFORMATION p I f 

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arent CompanY n orma o Parent Company Street Address- Line 1 Street Address- line2 City State Zip code Mailing Address (if different)· Line 1 Mailing Address (if different). Line 2 City State Zip code NumberofEmployees in Parent Company (circle one) 0-99 100-249 Dun and Bradstreet number Facility Information Please Numberthe FacUlties -+ Facility ___ Facility ID



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# J Mailing Address (ifdifferent)- Line 1 Mailing Address (ifdifferent)· Line 2 City State Zip code Number of employees at facility (circle one) 0-99 -<:'i9o-24U 250-499 >500 What is your size classification for HAP emissions? Major Source Area Source (Synthetic)



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# ---- Hours ofoperation for this facility (hrlyr) 

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# 7"a. Facility's primary NAICS or SIC code


## "~'//~~ Total Number of Periodic Kilns at this Facility



## ~ Total NumberofTunnel Kilns at this Facility



## ~ Contact Person forthis ICR 

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**.rm~7t+** Contact Phone Number 

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### ltJJ.~Mi-IJ. fl.sloA8.ttP!n.. keFAittrt;.t.r c.... I 250-499 >500 Please reprint the form to Include additionalfacilities Facility___ Facility

0-99 100-249 250-499 >500 0-99 100-249 250-499 >500 MajorSource Area Source (Synthetic) Not Sure Major Source Area Source (Synthetic) Not Sure

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## - FORM A· Po1gu 1 of

**~**INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY FORM B • KILN INFORMATION FACI!.IT and KILN IDs GENERAL INFORMATION Does this kiln have an Air Reporting Ifperiodic, number Pollution Control Year (if not ofidentical kilns Stack Device (APCD)? Facility ID Kiln ID(s) (a) 2007) Type of Kiln (b) on this line Year Built Diameter (ft) Yes or No



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**~71** GIN YIN YIN -y I N YIN YIN YIN Y/N Major Product Types Fired in Kiln 

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(a) Usethe ID from yourpermitorassign using TK-1, 2, etc. fortunnel and RK-1, 2, etc. for roller, and PK-1, 2, etc. for periodic. Use same IDthroughoutthisform. (b) Enteroneofthese: Tunnel Kiln, Roller Kiln, Shuttle Kiln, Other Periodic Kiln (c) Kiln size capacities should be In units oftons per hour (tph) offired product. KILN SIZE (c) Annual Operating Permitted Average/Actual Hours for Full Design Capacity (tph) if Capacity

Kiln Capacity (tph) applicable Utilization (o/o) (d) 

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(d) Forsources that have a maximum permitted production capacity higherthan the design capacity, enterthe actual capacity utlllzatlon,which is defined as the actual production divided bythe maximum permitted production rate. Forsources with an enforceable permit production limit lessthan the design capacity, enterthe average production capacity,which Is defined as theactual production divided bythe design capacity. FORM B ·Page 1 of2INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING

I NDUSTRY FORM B · KILN

I NFORMATION (Continued) FAC ILI TY and KIL N ID s

F U E L USAGE Percent Use of Secondary Fuel(% of operating Faci

l i t y ID K il n ID(s) ( a) Primary Fue l Secondary Fuel

t ime) Back-up Fuel ltf.-oJl.o RK..I /f) IITIJP.If.LCtf-.5 **~lt1** /<J Itt AI /fi **Jf-ol~o f?..~~<..:J**  f1)117UtUU- **r-~h** Alh fl/ 1!4 C.ll.S rJ tt--nJI..I'IJ;V /tt **~t** /1!//.} id' · -ol ;}-<)_ /{_KJ CM Reason(s) back- up would be used (e.g., NG curtailment) **~;,** d!Y-f **p~/l't** ADDITIONA L INFORMAT

I ON ON PER

I ODIC KILNS Average Average ti me Average

t i m e Total t i me back - Ave r age n um ber of requ ir ed to required to up f uel was Kiln ba tch batch balch load unfired un l oad fired used dur
i ng capacity cycle cycles per s h apes into shapes from yea r (hr) (tons) time (hr) year kiln (hr) kiln (hr) ,11/ I A. riA All It /lilt+- **/l(r~** /11/tf 111fA Nlrt rJh ,vh **~~~~** Alh /fl h **~t** /1/ff ;V/,r /h **~h** FORM 8 • P age 2 of 2INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY FORM C GLAZE APPLICATION INFORMATION FACILITY and GLAZE LINE lOs GENERAL INFORMATION Is this glaze line Controlled with an Annual Air Pollution Number of Reporting Operating Control Device Spray Booths Year(if not Hours for (APCD)? Yes or Facility 10 Glaze Line IO(s) (a) per Line 2007) Year Built Glaze Line No 

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# .... %ofHAP Containing HAP's Contained Glaze Annual Annual AMual Total of HAPs In Glazes Glazes that are spray

in Glazes (b) Consumption Consumption Units HAPs In Glazes Units applied (if known) 

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(b) Enter percentage ofspray booth operating timethat any glaze, which contains a metal HAP, Is applied In the booth.A "HAP containing glaze"ls any glazethatcontains a material or Ingredient listed as a metal HAP onthe MSOS forthat glaze/material.

FORM C • Page 1 of 1INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY FORM D ·KILN APCD INFORMATION 

# ··- APCD 

### lnformallon , 

# . Stack Facility 10 Kiln ID(s) (a) Diameter (ft) 

### ControiiD (b) Type (c) Reason Control was Installed (d) I 

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(a) Use the IDfrom your permit orassign using TK-1, 2, etc. for
**tunn~l** 

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(c) SelectOne: Dry LimestoneAdsorber (DLA), Dry. Injection 

### I Fabric Filter (DfFF), Dry Lime Scrubber (DLS), Wet Scrubber, Fabric Filter 

### I Baghouse Only, Lime System (unsure 

### If , DIFF or DLS), Spray Dryer 

### I Electrostatic Precipitator, Other.


## .. , 

### (d) Select One: Compfy,wlth MACT, become Synthetic Minor, S02Control, Particulate 

### I Opacity Control, Other. 

### FORM 0- Page 1 of4INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY FORM 0 KILN APCD INFORMAnON (Continued) . FACILITY and KILN IDs BAGHOUSEJFABRIC FILTER (Stand-alone or as part or DIFF or DLSl DIFForDLS Is reagent If recirculated, Total bag Avg. Life Total annual recirculated or average ratio of surface area Bag- material or or bags Air-to-Cloth Ratio Reagent feedrate reagent usage one-pass? recirculated to Facility 10 Kiln ID(s) (a) (ft2) construction (yrs) (see instructions) Cleaning method Reagent Type (value) Units/time (indicate units) (Enter one) fresh reagent ld-V 1)\1'\ l"of?17(, **f'~j!f.,~** /Ilk j **~t~ ~fJ.ull**  70 **rJ/~ A/~**  **tt~!rr** /8_:-0ik flK.I J( Fr7- S' /'Y)'t'?C"#/1 1- 7f1 f\JO tv/llr **~btntr'** 'f()() J I ,..,e, **~~e;z:r.~** I .

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### INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY FORM D - KILN APCD INFORMATION (Continued) FACILITY and KILN IDs Do you use reconditioning What is the rate atwhich Numberof drum/peeler? Yes limestone is removed from the Facility 10 Kiln ID(s) (a) cascades or No system as waste? 

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### FORM 0 • Page 3 of 4INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY FORM D ·KILNAPCD INFORMATION (Continued)

FACILITY and KILN IDs WET SCRUBBER Pressure drop pH range of Reagents used to Type ofscrubber liquid flow across scrubber scrubbing maintain pH in Facility 10 Kiln ID(s) (a) (e.g., venturi) rate (gpm) (inches ofwater) liquid desired range



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FORM 

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### INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY FORM E • GLAZE LINE APCD INFORMATION

FACILITY and GLAZE LINE IDs Facility ID Glaze Line ID(s) (a) ControiiD (b) 

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FORM E - Page 1 of 3INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY FORM E- GLAZE LINE APCD INFORMATION (Continued) FACILITY and GLAZE LINE IDs BAGHOUSE/FABRIC FILTER
WET SCRUBBER Pressure drop Total bag surface Avg. Life of bags Type of scrubber {e.g., Liquid flow rate across scrubber Facility ID Glaze Line ID(s) (a) area (ft2) Bag - material of construction (yrs) Cleaning method venturi) (gpm) {inches of water) 1/J.y **ttl~** f>oLYESTfft.. Fe'-'T **~~~~IL~i:.W ~~~**  **.J!IlJ(J~ D~t--rffl-**  J' **rn..t~ZJ+~.** 1'6 **/!.l&}£v~** }Jl-oJ:;J..o **(T~-o** #IO ,.,,... Soo!Jif'ttj s..! **~~~Ut- ~**  **~AI4"7£.4~~** fl}/t4 A!/14 Alh **~C.7H**

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r **~"""""** -OJ (a) Use the 10 from your permit or assign using GZ-1, 2, etc.

FORM E - Page 2 of 3INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY FORM E -GLAZE LINE APCD INFORMATION (Continued) FACILITY and GLAZE LINE IDs WATER CURTAIN OTHER CONTROL (please identify parameters and units monitored to verify contrails functioning properly) ues1gn or 1Jes1gn or ueslgn or Waterflow Width of water Equipped with baffle or Monitoring Monitoring Monitoring Facility ID Glaze line ID(s) (a) rate (gpm) curtain (ft) mist eliminator? (b) Parameter Units /Time Parameter Units /Time Parameter Units /Time **y;Jvll~** £.() ,. 77n'*IJ pll[JSvfL£.., **~~0\AI-)1 ~HUs**  hloNTifi,y b:_Z:o **~""'** a.UD a,.e. **J3~oJ~**

(81' Jl-• 0-+y **(j~~ oP~~**  \IZJUIIUY 6 7znt£J pa.tSSult£ **C-4141~¥1-V** f"'tCJ;'#"' /IJ,y ,e l'ltcrrTHL-y **18-ot~ G-~-1**  **fh~"roiLtl.)** 11- ()Ay **IJ~** flteott..Dl .:1 o PtAA7.7<1,J VA.rv-"£Ly 6 **~£)** piqJJUit.S:, **C!.t;f,.J1~:JJ~y** (f?OII"f»>,1 ,& **m01"171i~ Jf~OJ~**  G 2;-;;2.- **file~** ?&/ltL) /I My Otwr AlCcllA Cf. **Q.PFA.A-7~** Vj.§cJ-1U.y 6 72/ntJ **P/l.tJSU~'i,... ~,~or.IJ14**  fft)N7HJ.y /'nCJN/fiJ..y **IK;CI~** c;.&.-3 **tyttzh;..7uA~** l't OA-7 Q!t4J,4 **~~ 0~7**  **lf-cl~** G· Z:.- 'i Y.;t.JV.19L..l.'/ **~ ~EJ**  ptt.ESSf/14- **CcJ;tlf~CJJiry ~:8f"'or**  m **oN"?~ft,.y** tn a.AIP7dft{JJ ttOtty (Jtt-aP **0~"1~,./ Jf-ol~**  **t/~tJ,..U,Y**

' 'f"TAtJ PUJSvA-£ CC)AJ 1:z,JoiJJJ, )' **fk,~..II"Y** /11 **.~** J **G~-fJ tnCY"~**  **"7'c:J~ ~OP-** 

,..,.. .. **,,.~** }4 0.47' **()~ ai"~A-7~**  (a) Use the ID from your permit or assign using GZ-1, 2, etc. (b) Enter One: Baffles, Mist Eliminator, Both, or Neither.

FORM E - Page 3 of 3INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY FORM F- TEST DATA GENERAL INFORMATION TEST INFORMATION Kiln/Glaze Line/Stack FACIO ControiiD ID Test Date Report Date Type ofTest - Circle One 

# fotJGI Uncontrolled (or inletto control) HF 

## /tf.-oJ:JD "'



# -~ 

# "IJ 

# Jo!J.,_Jc,-

**td9~&,** eonrtol!ea) 

# ·"

**~/ltJIIJl** Both Uncontrolled (or inlet to control)



## Jf--o1~ **R_~** "''10-U£



## r~ 

# /o

# /1;)-br lo(q/Ob **~letl7** Bo 

# X

... 

# Jo

# (,,..lor io

# /r,Jot, Uncontrolled

**~r** inlet to control) 

# X ,,

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# lZK3
**a~7J** <e;;l trolled/ Both



# ~of:J.J **819~f~ovJt-** Uncontrolled.J.Q!l[llet to control)



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# io/rolo5' Jo

# ft

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# a~""""t **Uncontro~~~**control) 

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# lt'J~ i8"C/)O 

# fll • 3,; 1'1;) 

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# ~l BOth 

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### 13-o}~CJ 

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# 18--ota.Q 

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# loh



# /d~ <C_ontrolleO Both 

# ' Uncontrolled (or inlet to control) Controlled

Both Uncontrolled (or inlet to control) Controlled

Both Uncontrolled (or inlet to control) Controlled

Both POLLUTANTS TESTED (Please put X in box to indicate pollutant was tested) HAP HCI PM Metals Other (list below) Other (list below) Other (list below) : 

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# x: jo,_ 1/oc_ 

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Note: Please provide copies offull 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 ofthe reports, including sample calculations, laboratory data, run-by-run emission data, and a description of anydeviations 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 anec'dotal information you believe would potentially be helpful to us. 

### FORM F - Page 

### 1 of 2

### INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY FORM F ·TEST DATA (Continued) 

### GENERAL INFORMATION Kiln/Glaze Line/ Stack 

### FAC 10 ControiiD 10 

### ADDITIONAL INFORMATION Reasons for Test Notes



### FORM F • Page 2 of2

### INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY FORM G -MONITORING AND OTHER COSTS IFaclllty ID Unit Costs forJanuary 2008 Parameter Cost Electricity cost. $/kwh 

### Al)A**Re~M~_ent:** 

### AliAReagent Cost, $/ton



### ~!Jir Waste Reaaent disoosal cost, $/ton or $/vr 

## /lit!'# Water treatment costs, $/gal 

## /11/14 Estimated Staff Level - SelectOne Activity Required bv Activity Hours Frequency Operator, Maintenance, Engineer, Manager Develop a start-up, shutdown, and 

# I

**~vn- ~V~b**  

## /'hllZ/"'7£;fl

### ANC£.
**tnAN~** 

### malfunction plan Develop plan and educate staff 

### P..oNTtt.J 

## ,;.

**jn:J~ ~Het~c.r~**  Develop and implement an operating, **trvt~ZN7~**

## .4-vD£.

**f'lAt'V~rfi** maintenance, and monitoring plan Develop plan and educate staff 

# to tkJ



# ll.r-.-Jtl~ **1**



# "~ Standard Activities- Baghouse/DIFF/DLS · Bag replacement Reolace single baa

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### C.£, - 

# r: AJ

### 6--ZI"f£ffl., Bag replacement Replace all bags 

# .**~-.r** 

# '

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### /.MJC£...-

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## (21YJJ.c4u.,

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### G'ACC. , Maintain free-flowing lime (Describe action in 

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### Standard Aalvltles- DLA (limestone) Meet requirement to "maintain adequate 

## PIIYs~~,._..., me.AsuA-W 

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# /Wk.£ !11/.1-dA-H. A- - 

# e"'v;zRo'\111\



### ~L. amount of limestone in hopper." (Describe 

## Cat:JA-/l2r/A"'7tJA... 

## y:vy 

## 1J 

## It

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### CooA..I)~<+?al'-~ **Pll't"~f~c,** action taken in next box, then add estimated 

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### 'co~t~tJJI-.y hours, frequency, and staff level). If different 

### tno."9·:7rtl4f(} approaches are taken at different plants, 

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### A.o 

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### ~ut+fA..Y 

# 4k

# ""' StandardActivities- Wet ScrubberorOther Control Control Device: Compliance demonstration Activity (describe 

# A)L¥'r and estimate hours, frequency, and staff level) Compliance demonstration Activity (describe 

# f!(p and estimate hours, frequency, and staff level)_ I 

### Compliance demonstrationActivity (describe 

# rJifX and estimate hours, frequency, and staff level) FORM G • Page 1 of2

### INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY FORM G • MONITORING AND OTHER COSTS (Continued) lFacllity ID

StackTest Costs forthe Previous 3 Years 

### Uncontrolled (include uncontrolled stack orAPCD inlet}? Cost($) Staff Level • Select One 

### Operator, Maintenance, Engineer, Manager

Notes (Include Any site/preparation costs not included in estimate)

Please also provide separately an itemized list ofsite/preparation costs not included in the estimate (e.g., costs for drilling ports in stack, costs for installing permanent access to sampling ports, etc.)
FORM G • Page 2 of2INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY FORM H ·ECONOMICS IMPACT INFORMATION Product Selling Price Reporting Year for Average Selling Price Selling Price (if not Facility ID Product type per Ton($) 2007) I J> ·o J :;,.u /1 J! /A- AJ!t+ A/I ,A- , /"

labor Rates as of January 2008 Operator wage Maintenance wage Engineer wage Managerial/Supervisory rate, $/hr rate, $/hr rate, $/hr wage rate, $/hr ./1/4 /1/'jp **/1/~** /1/fo.; FORM H • Page 1 of 1INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY FORM

I ·ADDITIONAL QUESTIONS Question Please provide a copy of the cost estimate for your selected control tvlrr 1. 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 Do you currently do any work or operating practices (i.e., other than the 2. use of an air pollution control device) that would have an impact on HF, HCI, or PM emissions from your kilns? If yes, please explain. **;t)ottJ~** If you operate periodic kilns, please provide a time-temperature profile for each typical batch cycle. The profiles should show the duration of each 3. 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 (1}/ft for example profile.} 4. If you operate periodic kilns, do you have any information regarding technological and/or economic limitations to testing those kilns? rJIP! 5. Please provide a copy of a process flow diagram for your facility, if J/VC-1-I.l IJ€/j available.
Response FORM

I - Page 1 of 1

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# Sto!).epeak Ceramics, Inc. FacilityID: 18-0120 Emission Source #1 -RawMaterialsHandling ParticulateEmissions 

# r Baghouse #1 

# ·RawMaterialsStockPile Raw

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# StonepeakCeramics, Inc. FacilityID: 18-0120 EmissionSource#2 - Atomization

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# (Atomizers #1-#3) 

# Baghouse#2 

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# #6

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# Baghouse "'"" 

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# ·068 StonepeakCeramics, Inc. FacilityID: 18-0120 EmissionSource #4 - Firing Particulate,NOX, CO, S02,VOC, HF, Fluorides, HCI

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# Firing (Kilns

# #1 - #3) .n 

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# NaturalGas (CombinedMax. Capacity- 35.69MMBTU/Hr) Source #5 Product Preparation

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