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

FORM A - GENERAL INFORMATION

Parent Company Information

Parent Company General Shale Brick, Inc

Street Address- Line 1 3015 Bristol Highway

Street Address- Line 2

City Johnson City

State TN

Zip code 37601

Mailing Address (if different)- Line 1 PO Box 3547

Mailing Address (if different)- Line 2

City Johnson City

State TN

Zip code 37602

Number of Employees in Parent Company >500

Dun and Bradstreet number 79-3112848 

Facility Information

Facility 1 Facility 2 Facility 3 Facility 4 Facility 5 Facility 6 Facility 7 Facility 8

Facility ID GENE-18 GENE-1 GENE-2 GENE-3 GENE-19 GENE-16 GENE-17 GENE-4

Facility Name General Shale- Beltsville 

Facility General Shale Brick- Plant 42 General Shale Brick-Plant 10 General Shale Brick-Plant 18 General Shale Brick-Plant 30 General Shale Brick-Plant 31 General Shale Brick-Plant 37 General Shale Brick-Plant 38

Address 1 7100 Muirkirk Road 241 Hoyal Lane 102 South Broadway 13207 Memorial Prkwy 

South 3195 Brick Plant Road NW 2142 James Jackson State Route 655 212 South Park Road

Address 2

City Beltsville Spring City Johnson City Huntsville Atlanta Atlanta Somerset Fairsdale

County Prince Georges Rhea Washington Madison Fulton Fulton Orange Jefferson

State MD TN TN AL GA GA VA KY

Zip code 20705 37381 37601 35803 30318 30318 22972 40118

Mailing Address (if different)- Line 1

Mailing Address (if different)- Line 2

City

State

Zip code

Number of employees at facility Permanently Closed 45 67 Permanently Closed Permanently Closed Permanently Closed Permanently Closed 50

What is your size classification for HAP emissions? Major source Area Source (synthetic) Major source Major source Major source Major source Area Source (synthetic)

Hours of operation for this facility (hr/yr) 0 8760 8760 0 0 0 0 8760

Facility's primary NAICS or SIC code 327121 327121 327121 327121 327121 327121 327121 327121

Total Number of Periodic Kilns at this Facility 0 0 0 0 0 0 0 0

Total Number of Tunnel Kilns at this Facility 2 1 2 1 0 0 0 2

Contact Person for this ICR Warren Paschal Martha West Martha West Martha West Martha West Martha West Martha West Martha West

Contact Phone Number (919)774-5306 (423)952-4240 (423)952-4240 (423)952-4240 (423)952-4240 (423)952-4240 (423)952-4240 (423)952-4240

Contact Email Address warren.paschal@generalshal

e.com

martha.west@generalshale.c

om

martha.west@generalshale.c

om

martha.west@generalshale.c

om

martha.west@generalshale.c

om

martha.west@generalshale.c

om

martha.west@generalshale.c

om

martha.west@generalshale.c

om

090000648192f13c

FORM A - General Information
INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURING INDUSTRY

FORM A - GENERAL INFORMATION

Parent Company Information

Parent Company

Street Address- Line 1

Street Address- Line 2

City

State

Zip code

Mailing Address (if different)- Line 1

Mailing Address (if different)- Line 2

City

State

Zip code

Number of Employees in Parent Company

Dun and Bradstreet number

Facility Information

Facility ID

Facility Name

Address 1

Address 2

City

County

State

Zip code

Mailing Address (if different)- Line 1

Mailing Address (if different)- Line 2

City

State

Zip code

Number of employees at facility 

What is your size classification for HAP emissions?

Hours of operation for this facility (hr/yr)

Facility's primary NAICS or SIC code

Total Number of Periodic Kilns at this Facility

Total Number of Tunnel Kilns at this Facility

Contact Person for this ICR

Contact Phone Number

Contact Email Address

Facility 9 Facility 10 Facility 11 Facility 12 Facility 13 Facility 14 Facility 15 Facility 16

GENE-5 GENE-14 GENE-6 GENE-7 GENE-8 GENE-9 GENE-15 GENE-20

General Shale Brick-Plant 40 General Shale Brick-Plant 7 General Shale Brick-Plants 15 

& 29

General Shale Brick-Plants 

20, 32 & 43

General Shale Brick-Plants 35 

& 36

General Shale Brick-Plants 6 

& 28

General Shale- Corbin-Plant 

33

General Shale- Darlington 

Brick

121 Turner Bend Road 1740 Riverside Drive 100 Hill Street Old State Road Hwy 67 South 770 Webster Road Route 1 Hwy 11-E 16 Perkins Lane 602 Third & Morris Streets

Coosa Knoxville Kingsport Mooresville Blue Ridge Atkins Woodbine Darlington 

Floyd Knox Sullivan Morgan Botetourt Smyth Whitley Beaver

GA TN TN IN VA VA KY PA

30129 37901 37662 46158 24064 24311 40771 16115

Box 460 PO Box 346

43 Inactive 63 115 83 85 Inactive Permanently Closed

Major source Major source Major source Major source Major source Major source Major source Major source

8760 0 8760 8760 8760 8760 0 0

327121 327121 327121 327121 327121 327121 327121 327121

0 0 0 0 0 0 0 0

2 2 2 3 3 3 2 0

Martha West Martha West Martha West Warren Paschal Martha West Martha West Martha West Martha West

(423)952-4240 (423)952-4240 (423)952-4240 (919) 774-5306 (423)952-4240 (423)952-4240 (423)952-4240 (423)952-4240

martha.west@generalshale.c

om

martha.west@generalshale.c

om

martha.west@generalshale.c

om

warren.paschal@generalshal

e.com

martha.west@generalshale.c

om

martha.west@generalshale.c

om

martha.west@generalshale.c

om

martha.west@generalshale.c

om

090000648192f13c

FORM A - General Information
INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURING INDUSTRY

FORM A - GENERAL INFORMATION

Parent Company Information

Parent Company

Street Address- Line 1

Street Address- Line 2

City

State

Zip code

Mailing Address (if different)- Line 1

Mailing Address (if different)- Line 2

City

State

Zip code

Number of Employees in Parent Company

Dun and Bradstreet number

Facility Information

Facility ID

Facility Name

Address 1

Address 2

City

County

State

Zip code

Mailing Address (if different)- Line 1

Mailing Address (if different)- Line 2

City

State

Zip code

Number of employees at facility 

What is your size classification for HAP emissions?

Hours of operation for this facility (hr/yr)

Facility's primary NAICS or SIC code

Total Number of Periodic Kilns at this Facility

Total Number of Tunnel Kilns at this Facility

Contact Person for this ICR

Contact Phone Number

Contact Email Address

Facility 17 Facility 18 Facility 19 Facility 20 Facility 21

GENE-21 GENE-10 GENE-11 GENE-12 GENE-13

General Shale- Hanford 

Division-Plant 34

General Shale- Lee County 

Facility

General Shale- Moncure 

Facility

General Shale Robinson Brick 

Co.-Plant 2 General Shale- Sanford Plant

1136 Cedarcrest Drive 737 Colon Road 300 Brick Plant Road 1845 W. Dartmouth Avenue 1604 Colon Road

Burlington Sanford Moncure Denver Sanford

Alamance Lee Chatham Denver Lee

NC NC NC CO NC

27215 27330 27559 80110 27330

Permanently Closed Inactive 196 162 Inactive 30

Major source Major source Major source Major source

0 0 8760 8760 8760

327121 327121 327121 327121 3251

0 0 0 0 0

2 2 4 2 4

Warren Paschal Warren Paschal Warren Paschal Greg Knell Warren Paschal

(919) 774-5306 (919) 774-5306 (919) 774-5306 (303) 783-3061 (919) 774-5306

warren.paschal@generalshal

e.com

warren.paschal@generalshal

e.com

warren.paschal@generalshal

e.com

greg.knell@robinsonbrick.co

m

warren.paschal@generalshal

e.com

090000648192f13c

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) Back-up Fuel

Reason(s) backup would be 

used (e.g., NG 

curtailment)

GENE-18 tk-1 NA Tunnel-inactive NA NA NA NA No 12.00 NA NA Sawdust Natural Gas NA Natural Gas NA

GENE-18 tk-2 NA Tunnel-inactive NA NA NA No 6.00 NA NA Sawdust Natural Gas NA Natural gas NA

GENE-1 tk-1

Not 

Complete Tunnel 2008 4.00 Face brick 8760 Yes 20.55 NA NA Coal Natural gas 25 None NA

GENE-2 90-0046-07 - Kiln A 2006 Tunnel 1979 1.60 Face Brick 8760 No 7.60 8.33 80 Coal Natural gas 25 None NA

GENE-2 90-0046-07 - Kiln B 2006 Tunnel 1979 1.60 Face Brick 8760 No 9.20 9.2 80 Coal Natural gas 25 None NA

GENE-19 tk-1 Tunnel-inactive 1981 3.50 Face Brick 0 No 12.27 9.9 0 Coal Natural gas NA None NA

GENE-19 tk-2 Tunnel-inactive 1981 3.50 Face Brick 0 No 12.27 9.9 0 Coal Natural gas NA None NA

GENE-16 tk-1 Tunnel-inactive 1981 3.50 Face Brick 0 No 21.69 NA 0 Coal Natural gas NA None NA

GENE-17 tk-1 Tunnel-inactive 1965 3.20 Face Brick 0 No 9.75 NA 0 Natural gas None NA Propane NG curltailment

GENE-17 tk-2 Tunnel-inactive 1965 3.20 Face Brick 0 No 9.75 NA 0 Natural gas None NA Propane NG curltailment

GENE-17 tk-3 Tunnel-inactive 1957 3.20 Face Brick 0 No 9.75 NA 0 Natural gas None NA Propane NG curltailment

GENE--4 tk-1 2006 Tunnel 1996 3.67 Face Brick 8760 Yes 14.70 NA 72 Coal Natural gas 25 None NA

GENE--4 tk-2 2006 Tunnel 2004 3.94 Face Brick 8760 Yes 14.72 NA 72 Coal Natural gas 25 None NA

GENE-5 tk-1 2006 Tunnel 2003 4.90 Face brick 8760 Yes 18.75 18.75 70 Coal Natural gas 25 None NA

GENE-5 tk-2 2006 Tunnel 2003 4.90 Face brick 8760 Yes 18.75 18.75 70 Coal Natural gas 25 None NA

GENE-14 tk-1 Tunnel-inactive 1952 2.25 Face Brick 0 No 7.10 7.65 0 Coal Natural gas 25 None NA

GENE-14 tk-2 Tunnel-inactive 1964 3.00 Face Brick 0 No 13.22 9.9 0 Coal Natural gas 25 None NA

GENE-6 82-0036-06 Tunnel-inactive 1978 2.70 Face Brick 0 No 8.80 13.2 0 Natural gas None NA None NA

GENE-6 82-0036-25 2006 Tunnel 1979 4.00 Face Brick 8760 Yes 17.50 25.5 69 Coal Natural gas 25 None NA

GENE-7 tk-1 2006 Tunnel

1970 & 

1979 3.50 Face Brick 8760 Yes 14.80 14.8 64 Coal Natural gas 25 None NA

GENE-7 tk-2 2006 Tunnel 1987 3.50 Face Brick 8760 Yes 13.70 13.7 78 Coal Natural gas 25 None NA

GENE-7 tk-3 Tunnel 2007 4.00 Face Brick 8760 Yes 20.55 20.55 39 Coal Natural gas 25 None NA

GENE-8 tk-1 2006 Tunnel 1954 5.40 Face Brick 8760 Yes 10.10 8.2 87 Coal Natural gas 25 Propane NG curltailment

GENE-8 tk-2 2006 Tunnel 1954 5.40 Face Brick 8760 Yes 10.10 8.2 87 Coal Natural gas 25 Propane NG curltailment

GENE-8 tk-3 2006 Tunnel 1973 6.00 Face Brick 8760 Yes 22.00 17.5 50 Coal Natural gas 25 Propane NG curltailment

GENE-9 tk-1 Tunnel 1950 2.50

Face Brick, Brick 

Pavers 8760 No 3.68 21.9 for all 93 Coal Natural gas 25 None NA

GENE-9 tk-2 Tunnel 1950 2.50

Face Brick, Brick 

Pavers 8760 No 3.68 21.9 for all 93 Coal Natural gas 25 None NA

GENE-9 tk-3 Tunnel 1973 2.60

Face Brick, Brick 

Pavers 8760 Yes 15.02 21.9 for all 82 Coal Natural gas 25 None NA

GENE-15 tk-1 2006 Tunnel-inactive

1972 & 

1982 3.30 Face Brick 8760 No 9.90 9.9 75 Natural gas None

GENE-15 tk-2 2006 Tunnel-inactive 1987 4.30 Face Brick 8760 No 14.40 9.9 75 Natural gas None

GENE-20 tk-1 NA Tunnel-inactive 1955 2.00 NA 0 No 9.34 NA 0 Natural gas None

GENE-20 tk-2 NA Tunnel-inactive 1968 3.20 NA 0 No 2.39 NA 0 Natural gas None

GENE-21 tk-1 NA

Tunneldemolished NA NA NA NA No NA NA NA

GENE-21 tk-2 NA

Tunneldemolished NA NA NA NA No NA NA NA

GENE-10 ES-K1 NA Tunnel-inactive

circa 

1950s 2.50 Brick 8760 No 10.00 10.0 0 Sawdust Natural gas 20 Natural gas Emergency

GENE-10 ES-K2 NA Tunnel-inactive

circa 

1950s 2.50 Brick 8760 No 7.20 7.2 0 Sawdust Natural gas 20 Natural gas Emergency

GENE-11 ES-K1 NA Tunnel

circa 

1950s 2.50 Brick 8760 No 13.70 13.7 67 Sawdust Natural gas 20 Natural gas Emergency

GENE-11 ES-K2 NA Tunnel

circa 

1950s 2.50 Brick 8760 No 13.70 13.7 67 Sawdust Natural gas 20 Natural gas Emergency

GENE-11 ES-K3 NA Tunnel 1996 5.00 Brick 8760 Yes 20.55 20.55 50 Coal Natural gas 20 Natural gas Emergency

GENE-11 ES-K4 NA Tunnel 2005 5.00 Brick 8760 Yes 20.55 20.55 50 Coal Natural gas 20 Natural gas Emergency

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

090000648192f13c

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]

GENE-18 tk-1

GENE-18 tk-2

GENE-1 tk-1

GENE-2 90-0046-07 - Kiln A

GENE-2 90-0046-07 - Kiln B

GENE-19 tk-1

GENE-19 tk-2

GENE-16 tk-1

GENE-17 tk-1

GENE-17 tk-2

GENE-17 tk-3

GENE--4 tk-1

GENE--4 tk-2

GENE-5 tk-1

GENE-5 tk-2

GENE-14 tk-1

GENE-14 tk-2

GENE-6 82-0036-06

GENE-6 82-0036-25

GENE-7 tk-1

GENE-7 tk-2

GENE-7 tk-3

GENE-8 tk-1

GENE-8 tk-2

GENE-8 tk-3

GENE-9 tk-1

GENE-9 tk-2

GENE-9 tk-3

GENE-15 tk-1

GENE-15 tk-2

GENE-20 tk-1

GENE-20 tk-2

GENE-21 tk-1

GENE-21 tk-2

GENE-10 ES-K1

GENE-10 ES-K2

GENE-11 ES-K1

GENE-11 ES-K2

GENE-11 ES-K3

GENE-11 ES-K4

FACILITY and KILN IDs

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)

0 Yes NA NA NA NA

0 Yes NA NA NA NA

0

0

0

0

0

0

1752 Yes ES-2 2 100 100

1752 Yes ES-2 2 100 100

1752 Yes ES-WD1, 2 2 100 100

1752 Yes ES-WD1, 2 2 100 100

1752

1752

FOR SAWDUST FIRED KILNS ONLY ADDITIONAL INFORMATION ON PERIODIC KILNS

090000648192f13c

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

GENE-1 tk-1 diff-1

Dry Injection/Fabric Filter 

(DIFF) Other 1 2009 (not up yet) Hydrated lime anticipate 100 lbs/hr 150 15 0 0 NA

GENE-11 ES-K3 CD-K3DLA

Dry Limestone Scrubber 

(DLA)

Comply with 

MACT 1 2006 limestone 110 lbs/hr 150 75 0 0 NA

GENE-11 ES-K4 CD-K4DLA

Dry Limestone Scrubber 

(DLA)

Comply with 

MACT 1 2005 limestone 110 lbs/hr 150 75 0 0 NA

GENE-12 tk-1, tk-2 CD-1

Dry Limestone Scrubber 

(DLA)

Comply with 

MACT 2

2006 but still nonoperational limestone As noted- control has never been operated 

GENE-4 tk-1 dls/ff-1 Dry Lime Scrubber (DLS) Other 1 1997 Hydrated lime 140 lbs/hr 200 65 5040 0 NA

GENE-4 tk-2 dls/ff-2 Dry Lime Scrubber (DLS) Other 1 2005 Hydrated lime 140 lbs/hr 200 65 3600 0 NA

GENE-5 tk-1 diff-1

Dry Injection/Fabric Filter 

(DIFF) Other 1 2004 Hydrated lime 100 lbs/hr 125 5 0 0 NA

GENE-5 tk-2 diff-2

Dry Injection/Fabric Filter 

(DIFF) Other 1 2004 Hydrated lime 100 lbs/hr 125 5 0 0 NA

GENE-6 tk-2 diff-1

Dry Injection/Fabric Filter 

(DIFF) Other 1 2007 Hydrated lime 80 lbs/hr 150 27.25 0 0 NA

GENE-7 tk-1 diff-1

Dry Injection/Fabric Filter 

(DIFF) Other 1 2006

sodium 

bicarbonate 165/305 lbs/hr 125 30 0 0 NA

GENE-7 tk-2 diff-2

Dry Injection/Fabric Filter 

(DIFF) Other 1 2006

sodium 

bicarbonate 216 lbs/hr 125 30 0 0 NA

GENE-7 tk-3 diff-3

Dry Injection/Fabric Filter 

(DIFF) Other 1 2007

sodium 

bicarbonate 300 lbs/hr 125 30 0 Not measured NA

GENE-8 tk-1, tk-2 dla-1

Dry Limestone Scrubber 

(DLA)

Become Synthetic 

Minor 2 2004 limestone 92.7 lbs/hr 60 20 0 0 NA

GENE-8 tk-3 dla-2

Dry Limestone Scrubber 

(DLA)

Become Synthetic 

Minor 1 2006 limestone 200 lbs/hr 150 75 0 0 NA

GENE-9 tk-3 dla-1

Dry Limestone Scrubber 

(DLA)

Comply with 

MACT 1 not started yet limestone 180 lbs/hr 75 26 0 0 NA

DESIGN AND OPERATING PARAMETERS

090000648192f13c

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]

GENE-1 tk-1

GENE-11 ES-K3

GENE-11 ES-K4

GENE-12 tk-1, tk-2

GENE-4 tk-1

GENE-4 tk-2

GENE-5 tk-1

GENE-5 tk-2

GENE-6 tk-2

GENE-7 tk-1

GENE-7 tk-2

GENE-7 tk-3

GENE-8 tk-1, tk-2

GENE-8 tk-3

GENE-9 tk-3

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?

544 19 0.5 0.5

Woven fiberglass 

with PTFE 

membrane 1.5 On-line pulse jet 2.43:1 (normal) $30,000 53 One pass

Yes 

Yes

4

525 16 0.5 0.5 Goretex 1.5 On-line pulse jet 3.21:1 57,750 185 Recirculated Unknown

525 16 0.5 0.5 Goretex 1.5 On-line pulse jet 3.21:1 57,750 185 Recirculated Unknown

504 14 0.5 0.5

Woven fiberglass 

with PTFE 

membrane 1.5 On-line pulse jet 3.49:1 24,000 40 One pass

504 14 0.5 0.5

Woven fiberglass 

with PTFE 

membrane 1.5 On-line pulse jet 3.49.1 24,000 40 One pass

775 19 0.5 0.5

Woven fiberglass 

with PTFE 

membrane 1.5 On-line pulse jet 2.33:1 80,000

50 scfm@ 100 

psig One pass

544 19 0.5 0.5

Goretex or 

Equivalent 3 - 5 On-line pulse jet 49,000 45 One pass

450 19 0.5 0.5

Goretex or 

Equivalent 3 - 5 On-line pulse jet 41,000 45 One pass

544 19 0.5 0.5

Goretex or 

Equivalent 3 - 5 On-line pulse jet 49,000 45 One pass

One pass 5 Yes

One pass 7.5 No

One pass 5.7 Yes

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

090000648192f13c

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]

GENE-1 tk-1

GENE-11 ES-K3

GENE-11 ES-K4

GENE-12 tk-1, tk-2

GENE-4 tk-1

GENE-4 tk-2

GENE-5 tk-1

GENE-5 tk-2

GENE-6 tk-2

GENE-7 tk-1

GENE-7 tk-2

GENE-7 tk-3

GENE-8 tk-1, tk-2

GENE-8 tk-3

GENE-9 tk-3

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

Alternative

Remote visual 

insp.

Monitor Bypass 

Damper Position

Alternative

Remote visual 

insp.

Monitor Bypass 

Damper Position

Pressure Drop Other

Low level 

indicator light

Pressure Drop Other

Low level 

indicator light

Pressure Drop

Fill/discharge 

records

Low level 

indicator light

DLA

090000648192f13c

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

GENE-11 CD-K4DLA ES-K4 2/20/2006 Mar-06 Both x x x MACT Compliance Test

Limestone feed rate & 

pressure drop 19.93 PM outlet only

GENE-2 none

Kiln A 

/Stack 4 7/27-31/93 Oct-93 Uncontrolled X X X EPA stack test for AP-42 PM10, Nox, CO, THC, Methane/Ethane

GENE-4 dls/ff-1 Kiln 38 A 9/21/2001 Sep-01 Controlled X X Compliance Test

Lime Feed Rate, Differential 

Pressure 13.22 SO2, NOX

GENE-4 dls/ff-1 Kiln 38 A 12/18/2001 Dec-01 Controlled X Compliance Test

Lime Feed Rate, Differential 

Pressure ? SO2

GENE-4 dls/ff-2 Kiln 38 B 12/15/2005 Jan-06 Controlled X X X X Compliance Test

Lime Feed Rate, Differential 

Pressure 13.2 SO2, PM

GENE-5 diff-2

Kiln 40 

Unit K2 3/17/2005 Apr-05 Controlled X Permit Compliance Testing

Lime Feed Rate, Differential 

Pressure 7.2 SO2, four test runs conducted

GENE-5 diff-1&2

Kiln 40 

Units K1 

& K2 7/18-19/2007 Aug-07 Controlled X X X Permit Compliance Testing

Lime Feed Rate, Differential 

Pressure 16.3 SO2

GENE-5 diff-1

Kiln 40 

Unit K1 2/26/2008 Mar-08 Controlled X X X Permit Compliance Testing

Lime Feed Rate, Differential 

Pressure 16.9

SO2, Kiln K2 was not operating at the time of 

this test or it would be required to be tested 

as well.

GENE-5 diff-1

Kiln 40 

Unit K1 6/24/2008 Jun-08 Controlled X Permit Compliance Testing

Lime Feed Rate, Differential 

Pressure 16.9

SO2, Kiln K2 was not operating at the time of 

this test or it would be required to be tested 

as well.

GENE-7 DIFF-01

EU-002 

Line 1 11/2/2006 Dec-06 Controlled x x x SO2

, NOx Compliance Test Maintain free flowing reagent 12.41 12.41 tons/hr throughput

GENE-7 DIFF-02

EU-002 

Line 2 11/3/2006 Dec-06 Controlled x x x SO2

, NOx Compliance Test Maintain free flowing reagent 10.08 10.08 tons/hr throughput

GENE-7 DIFF-02

EU-002 

Line 2 1/24/2006 Jan-07 Controlled x x x SO2

, NOx Compliance Test Maintain free flowing reagent 11.11 11.11 tons/hr throughput

GENE-8 dla-1

Kilns 

35A&B 

Unit #05 2/23/2005 Mar-05 Controlled X X X Permit Compliance Testing

Lime Feed Rate, Differential 

Pressure 14.8 SO2

GENE-8 dla-2

Kiln 36 

Unit #06 11/29/2006 Dec-06 Both X X X Permit Compliance Testing

Lime Feed Rate, Differential 

Pressure 18.43 SO2, VEE

GENE-8 dla-2

Kiln 36 

Unit #06 3/14/2007 Apr-07 Both X X Permit Compliance Testing

Lime Feed Rate, Differential 

Pressure 16.6 Inlet & outlet HCI, HF

GENE-8 dla-2

Kiln 36 

Unit #06 8/22/2007 Sep-07 Both X X Permit Compliance Testing

Lime Feed Rate, Differential 

Pressure 17.7 Inlet & outlet HCI, HF

GENE-8 dla-2

Kiln 36 

Unit #06 5/20/2008 Jun-08 Both X X

Permit Compliance Testing & 

as part of Consent Agreement 

with Virginia DEQ

Lime Feed Rate, Differential 

Pressure 17.04 Inlet & outlet HCI, HF

GENE-8 dla-2

Kiln 36 

Unit #06 7/15/2008 Jul-08 Both X X

Permit Compliance Testing & 

as part of Consent Agreement 

with Virginia DEQ

Lime Feed Rate, Differential 

Pressure 15.88 Inlet & outlet HCI, HF

GENE-12 TK-1, TK-2 12/14-15/2004 Jan-05 Uncontrolled X X X X

Evaluate emissions prior to 

APCD selection Not Applic. see report SO2 lb/hr data in summary table incorrect

GENE-12 CD-1 TK-1, TK-2 3/1/2006

(no full report 

provided) Controlled X X X Evaluate CD-1 performance

No test report ever issued - only summary 

table

POLLUTANTS TESTED (Please put X in box to indicate pollutant 

was tested)

090000648192f13c

FORM D - Test Data 11/17/2014
INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURING INDUSTRY

FORM E - MONITORING AND OTHER COSTS

Facility ID - Representative DIFF

Unit Costs for January 2008

Parameter Cost

Electricity cost, $/kwh $0.085

Reagent: Hydrated Lime

Reagent Cost, $/ton $125.06

Waste Reagent disposal cost, $/ton $110.66

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 120 1/yr Manager

Develop and implement an operating, 

maintenance, and monitoring plan Develop plan and educate staff 120 1/yr Manager

Bag replacement Replace single bag 1 hr As needed Operator

Bag replacement Replace all bags 200 hrs As needed

Maintain free-flowing lime (Describe action 

in next box and then add estimated burden) 20 hrs Weekly Operator + 3 Maintenance

Daily Maintenance (list activity(ies) in next 

column)

clean educers and pipes, filters, 

downspout, check hoses, inspect and 

clean feeder, log readings and clean area. 5 hrs daily Operator

Weekly Maintenance (list activity(ies) in 

next column)

grease, inspect all motors actuators and 

control valves. 5 hrs weekly Operator

Monthly Maintenance (list activity(ies) in 

next column)

remove and clean vent pipe control 

plumbing. 8 hrs monthly Operator

Semi-Annual Maintenance (list activity(ies) 

in next column) remove baghouse top and inspect bags. 8 hrs semi annual Operator

Yearly Maintenance (list activity(ies) in next 

column)

replace bags(as recommended by 

Manufacturer) 200 hrs 2-3 years Operator + 1 Maintenance

Other Frequency Maintenance (specify 

frequency and list activity(ies) in next 

column) visible emissions test 10 min. daily Supervisor

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)

2005

2 Sources; EPA Methods 1,2.3A,4,6C,7E, 

& 10 Controlled $12,000.00

2007

2 Sources; EPA Methods 1,2.3A,4,6C,7E, 

& 10 Controlled $17,000.00

2008 EPA Methods 1-4, 6C, 26A Controlled $7,500.00

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)

Please provide actual costs for stack tests you have conducted in the past three years. Please list all test methods included in the test

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)

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- Wet Scrubber or Other Control

090000648192f13c

FORM E - Monit-Other Costs-DIFF 11/17/2014
INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURING INDUSTRY

FORM E - MONITORING AND OTHER COSTS

Facility ID - GENE 7

Please provide the following information for January 2008, if available for your facility

Electricity cost, $/kwh $0.0823

Reagent: sodium bicarbinate extra fine sorbin grade

Reagent Cost, $/ton $282.09

Waste Reagent disposal cost, $/ton $46.02

Water treatment costs, $/gal n/a

Operator wage rate, $/hr $15.46

Maintenance wage rate, $/hr $15.56

Engineer wage rate, $/hr $28.00

Managerial/Supervisory wage rate, $/hr $22.00

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 120 1/yr Manager

Develop and implement an operating, 

maintenance, and monitoring plan Develop plan and educate staff 120 1/yr Manager

Bag replacement Replace single bag 1 hr As needed Operator

Bag replacement Replace all bags 200 hrs As needed

Maintain free-flowing lime (Describe action in 

next box and then add estimated burden)

clean educers and pipes, filters, 

downspout, check hoses, inspect and 

clean feeder. 20 hrs Weekly Operator + 3 Maintenance

Daily Maintenance (list activity(ies) in next 

column)

clean educers and pipes, filters, 

downspout, check hoses, inspect and 

clean feeder, log readings and clean area. 5 hrs daily Operator

Weekly Maintenance (list activity(ies) in next 

column)

grease, inspect all motors actuators and 

control valves. 1 hr weekly Operator

Monthly Maintenance (list activity(ies) in 

next column)

remove and clean vent pipe control 

plumbing. 8 hrs monthly Operator

Semi-Annual Maintenance (list activity(ies) in 

next column) remove baghouse top and inspect bags. 8 hrs semi annual Operator

Yearly Maintenance (list activity(ies) in next 

column)

replace bags(as recommended by 

Manufacturer) 200 hrs 2 3 years Operator + 1 Maintenance

Other Frequency Maintenance (specify 

frequency and list activity(ies) in next 

column) visible emissions test 10 min. daily Supervisor

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)

Standard Activities- Wet Scrubber or Other Control

Standard Activities- Baghouse/DIFF/DLS

Standard Activities- DLA (limestone)

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)

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)
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)

2006

2 Sources EPA Methods 1-5, 6C, 7E, 9, 26A 

& 202 Controlled $12,000.00

2007 EPA Methods 1-5, 6C, 7E, 9, 26A & 202 Controlled $10,000.00

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

FORM E - MONITORING AND OTHER COSTS

Facility ID - Representative DLA

Unit Costs for January 2008

Parameter Cost

Electricity cost, $/kwh $0.0832

Reagent: Granulated Limestone

Reagent Cost, $/ton $81.46

Waste Reagent disposal cost, $/ton $65.00

Water treatment costs, $/gal None

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 120 hours 1/yr Manager

Develop and implement an operating, 

maintenance, and monitoring plan Develop plan and educate staff 120 hours 1/yr Manager

Bag replacement Replace single bag

Bag replacement Replace all bags

Maintain free-flowing lime (Describe action 

in next box and then add estimated 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)

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 Check bin indicators daily 0.5 hour Daily Operator

Daily Maintenance (list activity(ies) in next 

column)

3 visual inspections and dump the waste 

limestone hopper 1 hour Daily Operator

Weekly Maintenance (list activity(ies) in next 

column) Clean descaling filter 1 hour Weekly Maintenance

Monthly Maintenance (list activity(ies) in 

next column) Inspect the equip. and grease bearing. 2 hours Monthly Maintenance

Semi-Annual Maintenance (list activity(ies) in 

next column) Inspect the equip. and grease bearing. 2 hours Semi-Annual Maintenance

Yearly Maintenance (list activity(ies) in next 

column) Inspect the equip. and grease bearing. 2 hours Annually Maintenance

Other Frequency Maintenance (specify 

frequency and list activity(ies) in next 

column)

Dump grates will lock up during a power 

failure requiring 4 to 6 hours of maint. 

time. 4-6 hours As Needed Maintenance

Currently spending $12,000/month/DLA 

reagent costs with only one DLA in 

operation. This number will virtually double 

when the other DLA starts back up.

Control Device: 

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)

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- Wet Scrubber or Other Control
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)

2005 EPA Methods 1-5, 201A, 26A, 6C, & 9 Both $14,000.00

Install inlet ports 

$1,000

2006 EPA Methods 1-2, 3/3A, 4, 6C, 9 & 26A Both $17,500.00

2007 EPA Methods 1-4, 26A (Two times) Both $11,500.00

2008 EPA Methods 1-4, 26A Both $12,000.00

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)

Please provide actual costs for stack tests you have conducted in the past three years. Please list all test methods included in the test
INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURING INDUSTRY

FORM E - MONITORING AND OTHER COSTS

Facility ID - GENE 11

Please provide the following information for January 2008, if available for your facility

Electricity cost, $/kwh $0.0832

Reagent: Granulated Limestone

Reagent Cost, $/ton $81.46

Waste Reagent disposal cost, $/ton $65.00

Water treatment costs, $/gal None

Operator wage rate, $/hr $15.63

Maintenance wage rate, $/hr $18.59

Engineer wage rate, $/hr $28.00

Managerial/Supervisory wage rate, $/hr $22.00

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 120 hours 1/yr Manager

Develop and implement an operating, 

maintenance, and monitoring plan Develop plan and educate staff 120 hours 1/yr Manager

Bag replacement Replace single bag

Bag replacement Replace all bags

Maintain free-flowing lime (Describe action 

in next box and then add estimated 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)

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 Check bin indicators daily 0.5 hour Daily Operator

Daily Maintenance (list activity(ies) in next 

column)

3 visual inspections and dump the waste 

limestone hopper 1 hour Daily Operator

Weekly Maintenance (list activity(ies) in next 

column) Clean descaling filter 1 hour Weekly Maintenance

Monthly Maintenance (list activity(ies) in 

next column) Inspect the equip. and grease bearing. 2 hours Monthly Maintenance

Semi-Annual Maintenance (list activity(ies) in 

next column) Inspect the equip. and grease bearing. 2 hours Semi-Annual Maintenance

Yearly Maintenance (list activity(ies) in next 

column) Inspect the equip. and grease bearing. 2 hours Annually Maintenance

Other Frequency Maintenance (specify 

frequency and list activity(ies) in next 

column)

Dump grates will lock up during a power 

failure requiring 4 to 6 hours of maint. 

time. 4-6 hours As Needed Maintenance

Standard Activities- Baghouse/DIFF/DLS

Standard Activities- DLA (limestone)

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)

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)
Currently spending $2,000/month/DLA 

reagent costs

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)

2006

PM 26 A (outlet only)/HF & HCl 26 A (inlet 

& outlet) Both $10,000.00

Install inlet ports 

$1,000

Standard Activities- Wet Scrubber or Other Control

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

FORM E - MONITORING AND OTHER COSTS

Facility ID - GENE 4

Unit Costs for January 2008

Parameter Cost

Electricity cost, $/kwh $0.0823

Reagent: Hydrated Lime (Moistened)

Reagent Cost, $/ton $125.06

Waste Reagent disposal cost, $/ton $125.00

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 120 1/yr Manager

Develop and implement an operating, 

maintenance, and monitoring plan Develop plan and educate staff 120 1/yr Manager

Bag replacement Replace single bag 1 hr As needed Operator

Bag replacement Replace all bags 400 hrs As needed

Maintain free-flowing lime (Describe action in 

next box and then add estimated burden) 7 hrs Weekly Operator + 3 Maintenance

Daily Maintenance (list activity(ies) in next 

column)

clean educers and pipes, filters, 

downspout, check hoses, inspect and 

clean feeder, log readings and clean area. 3 hrs daily Operator

Weekly Maintenance (list activity(ies) in next 

column)

grease, inspect all motors actuators and 

control valves. 4 hrs weekly Operator

Monthly Maintenance (list activity(ies) in 

next column)

remove and clean vent pipe control 

plumbing. 8 hrs monthly Operator

Semi-Annual Maintenance (list activity(ies) in 

next column) remove baghouse top and inspect bags. 8 hrs semi annual Operator

Yearly Maintenance (list activity(ies) in next 

column)

replace bags(as recommended by 

Manufacturer) 400 hrs yearly Operator + 1 Maintenance

Other Frequency Maintenance (specify 

frequency and list activity(ies) in next 

column) visible emissions test 10 min. daily Supervisor

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)

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)

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)

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- Wet Scrubber or Other Control
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)

2006 EPA Methods 1-4, 3A, 6C, & 26A Controlled $9,000.00

Please provide actual costs for stack tests you have conducted in the past three years. Please list all test methods included in the test
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

A completed copy of this sheet is included in the Electronic submittal on CD because it contains classified information

090000648192f13c

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

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.

Yes. We use reduced draft firing as a method of changing the fire 

zone atmosphere while flashing. Reduction varies, but generally 

is 70% to 80% reduction for 1 to 1-1/2 minutes every 5 to 10 

minutes.

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 (Method Unknown): This was a one-time test at the 

different locations. Testing was performed from 1998-2000. The 

fluorides contained in the raw materials are as follow: GENE-6 

= 692 ppm; GENE-4 = 295 ppm; GENE-9 = 543 ppm; GENE-7 = 409 

ppm; GENE-1 = 680 ppm; GENE-14 = 460 ppm. These tests were 

performed by Mission Clay. For GENE-12:8 clay formulations 

tested (Cl via total halogen analysis and Fl via high temperature 

fusion and flouride ion specific electrode analysis, results in 

ppm); CHT: 327F, 24Cl - CNT: 377F, 27Cl - CR:433F, 56Cl - GT: 

398F, 29Cl - LFI: 437F, 22Cl - PK1: 328F, 21Cl - CB: 390F, 32Cl - 

COL: 489F, 30Cl. This analysis completed prior to first stack test 

to identify formulation to be tested to obtain "worst case" F 

emissions.

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. see above

5. If you operate periodic kilns, please provide a timetemperature 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. Not applic

6. If you operate periodic kilns, do you have any information 

regarding technological and/or economic limitations to 

testing those kilns? Not applic

7. Please provide a copy of a process flow diagram for your 

facility, if available.

090000648192f13c

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