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 ID

Kiln 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 Built

Stack Diameter 

(ft)

Major Products Types 

Fired in this Kiln (see 

list at bottom of 

spreadsheet)

Annual 

Operating 

Hours for Kiln

Does this kiln 

have an Air 

Pollution 

Control Device 

(APCD)?

 Full Design 

Capacity (tph)

Permitted 

Capacity (tph) 

if applicable

Actual 

Capacity 

Utilization (%) Primary Fuel Secondary 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-shuttle 1 1956 2.26 (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 KILN SIZE (a) FUEL USAGE

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 ID

Kiln 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 Fuel

Reason(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 Dryer

Average percent of 

operating time this 

kiln vents to dryer

Average 

percent of flow 

sent to dryer

Kiln batch 

capacity 

(tons)

Average batch 

cycle time (hr)

Average 

number of 

batch cycles 

per year

Average time 

required to load 

unfired shapes 

into kiln (hr)

Average time 

required to 

unload fired 

shapes from kiln 

(hr)

None

None

None 250 168 14 20 20

None

None

None

None

None

None

None

None

None

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

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 ID

Kiln 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 device

Year control device 

was installed Reagent Type

Reagent 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 

bicarbonate

Hydrated: 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 & P2KILBAG

Dry Injection/Fabric Filter 

(DIFF) SO2 control 1 2000

hydrated lime & 

sodium 

bicarbonate

Hydrated: 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 ID

Kiln 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 bags Bags- Length (ft) Bags- Width (ft) Bags- Diam (ft)

Bag- material of 

construction

Avg Life of bags 

(yrs) Cleaning method Air-to-cloth ratio

Cost 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

BAGHOUSE/FABRIC FILTER (Stand-alone or as Part of DLS/DIFF system) DIFF or DLS DLA

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 ID

Kiln 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 ID

Kiln/ 

Stack ID Test 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 Opacity Permit 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, 

PMCondensible Permit compliance see report7.09 ton/hr mostly fireclay 

product

BELD-1

P601-

P603 5/30/2007 Uncontrolled x

SO2, NOx, CO, 

PMCondensible Permit 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 Opacity Permit 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, 

PMCondensible Permit 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 11/17/2014
FACILITY: 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 40 once/yr Engineer

Develop and implement an operating, 

maintenance, and monitoring plan Develop plan and educate staff 40 once/yr Engineer

Bag replacement Replace single bag 3 once/yr Maintenance

Bag replacement Replace all bags 120 evey 4 years Maintenance 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.

CORPSIZE HAPSIZE KILNTYPE FUEL SECFUEL CONTROL REASON YESNO TESTS STAFF RECIR DLA1 DLA2 Yes

 0-99 Major source Tunnel Natural gas None

Dry Limestone 

Adsorber (DLA)

Comply with 

MACT Yes Uncontrolled Operator Recirculated

Pressure 

Drop

Daily climb to 

hopper

100-249 Area Source (true)

Tunnel- low profile or 

roller Sawdust

Natural 

gas

Dry Injection/Fabric 

Filter (DIFF)

Become 

Synthetic 

Minor No Controlled Maintenance One pass Alternative

Remote visual 

insp.

249-499 Area Source (synthetic) Tunnel-inactive Coal Sawdust

Dry 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 Oil

Fabric Filter/ 

Baghouse only Other

Periodic-beehive Other Propane

Lime system 

(unsure if DIFF or 

DLS)

Landfilll/ 

Biogas

Spray Dryer/ 

Electrostatic 

Precipitator

Other Other