### INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURING INDUSTRY

**FORM A - GENERAL INFORMATION**

**Parent Company Information** Parent Company Belden Brick Company Street Address- Line 1 700 W. Tuscarawas Street Street Address- Line 2 P.O. Box 20910 City Canton State OH Zip code 44701-0910 Mailing Address (if different)- Line 1 Mailing Address (if different)- Line 2 City State Zip code Number of Employees in Parent Company >500 (total employees equals 500) Dun and Bradstreet number 00-446-8690

**Facility Information**

Facility 1 Facility 2 Facility 3 Facility 4 Facility 5 Facility 6 Facility 7 Facility ID BELD-1 BELD-2 Facility Name Belden- Plants 2, 3, 4 ,6 ,8 &9 Sugarcreek Belden- Plant 1 Strasburg
Address 1 225 E Main Street 7666 Reed Road NW Address 2 City Sugarcreek Strasburg County Tuscarawas Tuscarawas State OH OH Zip code 44681 44680 Mailing Address (if different)- Line 1 Mailing Address (if different)- Line 2 City State Zip code Number of employees at facility 500 2 What is your size classification for HAP emissions? Major source Hours of operation for this facility (hr/yr) 8760 0 Facility's primary NAICS or SIC code 327121 327121 Total Number of Periodic Kilns at this Facility 20 0 Total Number of Tunnel Kilns at this Facility 10 1 Contact Person for this ICR Bradley Belden Bradley Belden Contact Phone Number 330-852-2424 330-852-2424
Contact Email Address bradley.belden@beldenbrick.

com bradley.belden@beldenbrick.

com

090000648192f15f FORM A - General Information

### INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS 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 and PK1,2, etc for periodic]Reporting year

(if not 2007) Type of Kiln If periodic, number of identical kilns included on this line Year BuiltStack Diameter (ft) Major Products Types

Fired in this Kiln (see list at bottom of spreadsheet) Annual

Operating Hours for KilnDoes this kiln

have an Air Pollution Control Device (APCD)? Full Design

Capacity (tph) Permitted

Capacity (tph) if applicable Actual

Capacity Utilization (%)Primary FuelSecondary Fuel Percent Use of Secondary Fuel (% of operating time)

BELD-1 P201 

### Tunnel 2000 4.75 face brick, fireclay and/or shale, special shapes, flashed 8760 Yes 10.65 

### 66.8% Natural gas None

BELD-1 P301 

### Tunnel 1980 4.00 molded face brick, fireclay and/or shale, special shapes, flashed 8760 Yes 13.70 

### 54.8% Natural gas None

BELD-1 P401-P420 

### Periodic-beehive 20 1928 6.67 face brick, fireclay and/or shale, special shapes, pavers, flashed N/A No N/A Natural gas None

BELD-1 P601 

### Tunnel 1956 5.75 face brick, fireclay and/or shale, special shapes, pavers 8760 No 5.32 

### 60.8% Natural gas None

BELD-1 P602 

### Tunnel 1956 5.75 face brick, fireclay and/or shale, special shapes, pavers 8760 No 5.32 

### 61.2% Natural gas None

BELD-1 P603 

### Tunnel 1956 5.75 face brick, fireclay and/or shale, special shapes, pavers 8760 No 5.32 

### 69.1% Natural gas None BELD-1 P675 

### Periodic-shuttle1 19562.26 (2 stacks)glazed brick N/A No N/A Natural gas None

BELD-1 P801 

### Tunnel 1964 5.25 molded face brick, fireclay-shale mix, special shapes, flashed 8760 Yes 7.77 

### 83.0% Natural gas None

BELD-1 P802 

### Tunnel 1964 5.25 face brick, fireclay and/or shale, special shapes, flashed 8760 Yes 7.77 

### 82.1% Natural gas None

BELD-1 P803 

### Tunnel 1964 5.25 face brick, fireclay and/or shale, special shapes, flashed 8760 Yes 7.77 

### 82.0% Natural gas None

BELD-1 P101 

### Tunnel 1963 3.00 face brick, fireclay and/or shale, special shapes, flashed 8760 No 3.05 

### 77.4% Natural gas None

BELD-1 P102 

### Tunnel 1963 3.00 face brick, fireclay and/or shale, special shapes 8760 No 3.05 

### 77.7% Natural gas None 

### FACILITY and KILN IDs GENERAL INFORMATION FUEL USAGE KILN SIZE**(a)**

090000648192f15f FORM B - Kiln Information 11/17/2014

### INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS 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 and PK1,2, etc for periodic]

BELD-1 P201

BELD-1 P301

BELD-1 P401-P420

BELD-1 P601

BELD-1 P602

BELD-1 P603 BELD-1 P675

BELD-1 P801

BELD-1 P802

BELD-1 P803

BELD-1 P101

BELD-1 P102 

### FACILITY and KILN IDs

Back-up FuelReason(s) backup would be used (e.g., NG curtailment)Total time backup fuel was used during year (hr) Do you vent

this kiln to a sawdust dryer? Sawdust

Dryer ID (Assign)Total Number

of kilns vented to this DryerAverage percent of

operating time this kiln vents to dryer Average

percent of flow sent to dryerKiln batch

capacity (tons) Average batch

cycle time (hr)Average

number of batch cycles per year Average time

required to load unfired shapes into kiln (hr) Average time

required to unload fired shapes from kiln (hr)

None

None

None 

### 250 168 14 20 20

None

None

None None

None

None

None

None

None 

### ADDITIONAL INFORMATION ON PERIODIC KILNS FOR SAWDUST FIRED KILNS ONLY FUEL USAGE

090000648192f15f FORM B - Kiln Information 11/17/2014**INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURING INDUSTRY FORM C - APCD INFORMATION** 

FACILITY AND KILN IDs

Facility IDKiln ID(s) [Use the ID

from your permit or assign using TK-1, 2, etc for tunnel and PK-1,2, etc for periodic] 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 installed Reagent TypeReagent feedrate (value) Units/ time Total fan hp Total hp for other motors Water usage

(gpd) Added cooling

air, acfm Other utility

requirements Units/time

BELD-1 P301 P3KILNSCR & P3KILNBAG Dry Injection/Fabric Filter

(DIFF) SO2 control 1 1999 hydrated lime & sodium bicarbonateHydrated: 0 to

380. Sodium Bicarbonate: 0 to 330 lb/hr 125 170+/- N/A System has cool air bleed, for safety but is not needed for operation.

BELD-1 P801-P803 P8SCRUB Spray Dryer/ Electrostatic Precipitator SO2 control 3 2003 Lime slurry 0 to 5 gpm 250 399+/- 6 to 19 temp dependent N/A

BELD-1 P201 P2KILSCR & P2KILBAGDry Injection/Fabric Filter (DIFF) SO2 control 1 2000 hydrated lime & sodium bicarbonateHydrated: 0 to

380. Sodium Bicarbonate: 0 to 840 lb/hr 150 195+/- N/A System has cool air bleed, for safety but is not needed for operation. DESIGN AND OPERATING PARAMETERS

090000648192f15f FORM C - APCD Info 11/17/2014**INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURING INDUSTRY FORM C - APCD INFORMATION** 

Facility IDKiln ID(s) [Use the ID

from your permit or assign using TK-1, 2, etc for tunnel and PK-1,2, etc for periodic]

BELD-1 P301

BELD-1 P801-P803

BELD-1 P201 Number of bagsBags- Length (ft)Bags- Width (ft)Bags- Diam (ft)Bag- material of construction Avg Life of bags

(yrs) Cleaning methodAir-to-cloth ratioCost of full set of bags Avg. compressed

air requirements, acfm 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?

560 121.75" 6.25" Fiberglass with PTFE membrane 3 to 5 Plenum pulse 52696 One pass

N/A N/A N/A N/A N/A N/A N/A N/A One pass

504 121.75 6.25" Fiberglass with PTFE membrane 3 to 5 Plenum pulse 47426 One pass DLA DIFF or DLS BAGHOUSE/FABRIC FILTER (Stand-alone or as Part of DLS/DIFF system)

090000648192f15f FORM C - APCD Info 11/17/2014**INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURING INDUSTRY FORM C - APCD INFORMATION** 

Facility IDKiln ID(s) [Use the ID

from your permit or assign using TK-1, 2, etc for tunnel and PK-1,2, etc for periodic]

BELD-1 P301

BELD-1 P801-P803

BELD-1 P201 WET SCRUBBER OTHER CONTROL (please identify parameters and units monitored to verify control is functioning properly)

If complying with the MACT, do you monitor pressure drop or

use an alternative?If complying with

the MACT, how do you verify sufficient limestone in hopper? Explain Other or

Alternative Type of scrubber

(e.g., venturi)Liquid flow rate

(gal/min) Pressure drop

across scrubber (inches of water) Design or

Monitoring Parameter Units / Time Design or Monitoring Parameter Units / Time Design or Monitoring Parameter Units / Time DLA

090000648192f15f FORM C - APCD Info 11/17/2014**INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURING INDUSTRY**

**FORM D - TEST DATA**

GENERAL INFORMATION TEST INFORMATION ADDITIONAL INFORMATION

FAC ID Control IDKiln/ Stack IDTest Date Report Date Type of TestUncontrolled (or inlet to control), Controlled, Both HF HCl PM HAP Metals Other Reasons for Test APCD Parameters Monitored During Test Production rate of fired product during test (tph) Notes 

### This test does not repeat test reports submitted during EPA's previous ICR survey in 1998.

BELD-1 P3KILNSCR &

P3KILNBAG P301 5/1/2001 Controlled x x x SO2, NOx, CO see report 13.97 ton/hr fireclay product

BELD-1 P3KILNSCR &

P3KILNBAG P301 8/24/2005 Controlled x x x SO2, NOx, CO,PMCondensible, Visible OpacityPermit compliance see report 11.03 ton/hr fireclay product. RATA failed for NOx & CO.

BELD-1 N Stack P411- P420 6/11/2007 Uncontrolled x SO2, NOx, CO,PMCondensiblePermit compliance see report 7.09 ton/hr mostly fireclay product

BELD-1 P601- P603 5/30/2007 Uncontrolled x SO2, NOx, CO,PMCondensiblePermit compliance see report 7.09 ton/hr mostly fireclay product. First stack test with new combined stack for all kilns. Test results still in debate due to test port location.

BELD-1 Kiln 1 P801- P803 9/27/2001 Uncontrolled x x x SO2, NOx, CO see report 12.6 ton/hr

BELD-1 P8SCRUB P801- P803 8/26/2003 Controlled x x x SO2, NOx, CO see report PM, HF & HCl tests were rejected because they did not follow proper test method.

BELD-1 P8SCRUB P801- P803 8/23/2005 Controlled x PMCondensible, Visible OpacityPermit compliance see report 20.86 ton/hr mostly fireclay product.

BELD-1 P102 5/1/2001 Uncontrolled x x x SO2, NOx, CO see report 2.47 ton/hr fireclay product.

BELD-1 P101- P102 5/31/2007 Uncontrolled x SO2, NOx, CO,PMCondensiblePermit compliance see report 4.93 ton/hr fireclay product. First stack test with new combined stack for both kilns. POLLUTANTS TESTED (Please put X in box to indicate pollutant was tested)

090000648192f15f FORM D - Test Data 11/17/2014FACILITY: BELD-1

Please provide the following information for January 2008, if available for your facility Electricity cost, $/kwh 0.06 $ Reagent: Hydrated Lime Reagent Cost, $/ton 135.00 $ Reagent: Sodium Bicarbonate Reagent Cost, $/ton 333.00 $ Waste Reagent disposal cost, $/ton 28.00 $ Disposal $ is for for both lime & bicarb Water treatment costs, $/gal N/A

Based on your experience complying with the now-vacated MACT, please provide as much information as possible below.

Activity Required by Activity Estimated Hours Frequency Staff Level Develop a start-up, shutdown, and malfunction plan Develop plan and educate staff 40once/yr Engineer Develop and implement an operating, maintenance, and monitoring plan Develop plan and educate staff 40once/yr Engineer

Bag replacement Replace single bag 3once/yr Maintenance Bag replacement Replace all bags 120evey 4 yearsMaintenance time includes baghouse cool down time and baghouse warm up
Maintain free-flowing lime (Describe action in next box and then add estimated burden)N/A, we do not require free-flowing reagent.

Daily Maintenance (list activity(ies) in next column) separate sheet 3 Operator Weekly Maintenance (list activity(ies) in next column) separate sheet 3 Operator Monthly Maintenance (list activity(ies) in next column) separate sheet 2 Maintenance Semi-Annual Maintenance (list activity(ies) in next column) separate sheet 3 Maintenance Yearly Maintenance (list activity(ies) in next column) separate sheet 6 Engineer Other Frequency Maintenance (specify frequency and list activity(ies) in next column) separate sheet

Meet requirement to "maintain adequate amount of limestone in hopper." (Describe action taken in next box, then add estimated burden). If different approaches are taken at different plants, please add rows and provide information on each approach

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

Control Device: Compliance demonstration Activity (describe and estimate burden) Compliance demonstration Activity (describe and estimate burden) Compliance demonstration Activity (describe and estimate burden)

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

Test Costs

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) RATA- $12,500, regular stack test $6-8,000*See test reports sent under different copy. Please provide actual costs for stack tests you have conducted in the past three years. Please list all test methods included in the test On-going Maintenance ( Please complete for one representative DLA within your company. In lieu of completing this table, submit list of

maintenance activities from your OMMP and provide estimate of hours/labor beside the table) Standard Activities- Baghouse/DIFF/DLS

On-going Maintenance ( Please complete for one representative DIFF/DLS within your company. In lieu of completing this table, submit copy

of maintenance activities from your OMMP and provide estimate of hours/labor beside the table)

Standard Activities- DLA (limestone)

Standard Activities- Wet Scrubber or Other Control

On-going Maintenance ( Please complete for one representative other control within your company. In lieu of completing this table, submit

list of maintenance activities from your OMMP and provide estimate of hours/labor beside the table)

090000648192f15f FORM E - Monit-Other Costs 11/17/2014

# INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURING INDUSTRY

**FORM F - 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 BELD-1 Face Brick & Pavers 19.00 $ 20.00

$ 25.00

$ 35.00

$

090000648192f15f FORM F - Economics Info 11/17/2014

# INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURING INDUSTRY

**FORM G - 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 Plt 2 - $2.34 Million, Plt 3 $1.79 Million, Plt 8 $3.27 Million

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. Push rate variation and kiln car load variation would have (ton/hr) will have an impact on emissions. Flashing will also impact PM emissions. 3. Do you have any data available on the fluorine or chlorine contents of your raw materials? If yes, please explain the types of information you have, the test method used to determine these contents, the frequency in which you test your raw materials, and any other information you feel is relevant to this discussion. Yes. We don’t typically test for these parameters, but we did test for chlorine in 2004 as part of a research project. The results are from an XRF machine. 4. If you answered YES to #3, please include copies of your raw material testing for either: the past two months OR the past 10 tests, whichever is more. Please indicate which you are submitted in the response section to this question. There were 28 samples taken during the test, and all results indicated that Cl content was less than 50 ppm.

5. 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.) Also provide the additional information requested on Form B. Pre-heat to top temp - 81 hours; top temp & flash - 60-72 hours; cool down - 144 hours
6. If you operate periodic kilns, do you have any information regarding technological and/or economic limitations to testing those kilns? No. 7. Please provide a copy of a process flow diagram for your facility, if available. Not available.

090000648192f15f FORM G - Additional Questions 11/17/2014

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

CORPSIZEHAPSIZE KILNTYPE FUEL SECFUELCONTROL REASON YESNO TESTS STAFF RECIR DLA1 DLA2 Yes

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

MACT Yes Uncontrolled Operator RecirculatedPressure Drop Daily climb to

hopper

100-249Area Source (true) Tunnel- low profile or roller Sawdust Natural gas Dry Injection/Fabric

Filter (DIFF) Become

Synthetic Minor No Controlled Maintenance One pass AlternativeRemote visual insp.

249-499Area Source (synthetic) Tunnel-inactive Coal SawdustDry Lime Scrubber (DLS) SO2 control Both Engineer Fill/discharge records

>500 Not sure Periodic Fuel Oil Coal Wet Scrubber Particulate/ opac. control Manager Other

Periodic-shuttle Landfill/Biogas Fuel OilFabric Filter/ Baghouse only Other

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

Electrostatic Precipitator Other Other