### INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY

**FORM A - GENERAL INFORMATION**
**Parent Company Information** Parent Company 

### Panaria Group Street Address - Line 1 

### Panaria Bassa, 22/a Street Address - Line 2 

### 41034 Finale Emilia City 

### Modena State 

### Italy Zip code Mailing Address (if different) - Line 1 

### 320 W. Main St. Mailing Address (if different) - Line 2 City 

### Lakeland State 

### FL Zip code 

### 33815 Number of Employees in Parent Company 

### >500 Dun and Bradstreet number 

### 00 409 1583

**Facility Information** Facility 1 Facility 2 Facility 3 Facility 4 Facility 5 Facility 6 Facility 7 Facility ID 2100500008 Facility Name Florida Tile Inc Address 1 1247 Alton Rd Address 2 City Lawrenceburg County Anderson State Kentucky Zip code 40008 Mailing Address (if different) - Line 1 Mailing Address (if different) - Line 2 City State Zip code Number of employees at facility 100-249 What is your size classification for HAP emissions? Area Source (synthetic) Hours of operation for this facility (hr/yr) 6000 Facility's primary NAICS or SIC code 327122 Total Number of Periodic Kilns at this Facility 0 Total Number of Tunnel Kilns at this Facility 0 Contact Person for this ICR David M. Johnston Contact Phone Number 502-839-6911 ext 238 Contact Email Address mike.johnston@floridatile.com

EPA-HQ-OAR-2013-0290-DRAFT-0016 FORM A - General Information 12/1/2014

### INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY **INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY FORM B - KILN INFORMATION** 

Facility ID Kiln ID(s)[Use the

ID from your permit or assign using TK-1,2, etc for tunnel, RK1, 2, etc for roller, and PK-1, 2, etc for periodic] Reporting Year (if

not 2007) Type of Kiln If periodic, number of identical kilns on this line Year Built Stack Diameter (ft)Does this kiln

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

Operating Hours for Kiln Full Design

Capacity (tph) Permitted

Capacity (tph) if applicableAverage/Actual

Capacity Utilization (%) **(a)** Primary Fuel

2100500008RK-1 Roller Kiln No Wall Tile Natural gas

2100500008RK-2 Roller Kiln No Wall Tile 0 Natural gas

2100500008RK-5 Roller Kiln No Wall Tile Natural gas

2100500008RK-6 Roller Kiln 2007 No Deleted as CBI Deleted as CBI Natural gas

2100500008RK-1 Roller kiln 1996 No Deleted as CBI Deleted as CBI

2100500008RK-2 Roller kiln 1996 No Deleted as CBI Deleted as CBI

2100500008RK-5 Roller kiln 1995 No Deleted as CBI Deleted as CBI

 Permit restriction to only run either Kiln 1 OR 5 until modeling complete. Modeling has been completed. Market conditions are such that we still only run one Kiln or the**  *** Only operational July - Dec. Current scheduled to run 24/5/48 or 5760. (a) For sources that have a maximum permitted production capacity higher than the design capacity, enter the actual capacity utilization, which is defined as the actual production divided by the maximum permitted production**  **rate. For sources with an enforceable permit production limit less than the design capacity, enter the average production capacity, which is defined as the actual production divided by the design capacity.** KILN SIZE FACILITY and KILN IDs GENERAL INFORMATION

EPA-HQ-OAR-2013-0290-DRAFT-0016 FORM B - Kiln Information 12/1/2014

### INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY **INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY FORM B - KILN INFORMATION** 

Facility ID Kiln ID(s)[Use the

ID from your permit or assign using TK-1,2, etc for tunnel, RK1, 2, etc for roller, and PK-1, 2, etc for periodic]

2100500008RK-1

2100500008RK-2

2100500008RK-5

2100500008RK-6

2100500008RK-1

2100500008RK-2

2100500008RK-5

**(a) For sources that have a maximum permitted production capacity higher than the design capacity, enter the actual capacity utilization, which is defined as the actual production divided by the maximum permitted production rate. For sources with an enforceable permit production limit less than the design capacity, enter the average production capacity, which is defined as the actual production divided by the design capacity.**  FACILITY and KILN IDs ADDITIONAL INFORMATION ON PERIODIC KILNS

Secondary Fuel Percent Use of

Secondary Fuel (% of operating time) Back-up FuelReason(s) backup would be used (e.g., NG curtailment)Total time backup fuel was used during year (hr) Kiln batch

capacity (tons)Average

batch cycle time (hr) Average

number of batch cycles per year Average time

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

required to unload fired shapes from kiln (hr)

0% Propane NG curtailment 0

0% Propane NG curtailment 0

0% Propane NG curtailment 0

0% Propane NG curtailment 0 FUEL USAGE

EPA-HQ-OAR-2013-0290-DRAFT-0016 FORM B - Kiln Information 12/1/2014**INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY**

**FORM C - GLAZE APPLICATION INFORMATION** GENERAL INFORMATION

Facility ID Glaze Line ID(s)

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

Booths Per Line Reporting Year (if not 2007) Year Built Annual Operating Hours for Glaze Line Is this Glaze Line Controlled by

an Air Pollution Control Device

(APCD)? Average

Percentage of HAP's Contained in Glazes (a) Glaze Annual

ConsumptionAnnual Consumption Units (H)*(I)

.... Annual Total of HAPs In Glazes HAPs In Glazes

Units % of HAP

Containing Glazes that are spray applied (if known) Decorating line #1 1 1996 Yes Decorating Line #2 2 1996 Deleted Yes Decorating Line #5 2 1995/1996 as Yes Decorating Line #6 7 2006 CBI Yes decorating line #7 8 2006 Yes

90% hydrofilters 98.7% dust collectors

**Total 2007 Total 2007**  **Total 2007 Total 2007** **Total 2007 Total 2007**  **Zinc Chrome**  **Cobalt Iron**  **Nickel Manganese** 

**0 0**  **1 0**  **2 0**  **31 47**  **78 0**  **0 0**  **67 67**  **0 0**  **0 0**  **31 514**  **62 0**  **0 0**  **376 276**  **0 0**  **0 0**  **834 196**  **0 0**  **0 0**  **58 74**  **0 0**  **26 0**  **130 95**  **0 0**  **0 0**  **Deleted 1**  **4 7**  **0 0**  **0 0**  **0 391**  **0 0**  **0**
**as 16**  **0 5**  **0 0**  **0 0**  **2 0**  **0 0**  **0 CBI**  **0 61**  **65 0**  **0 0**  **714 0**  **0 0**  **0 0**  **1027 0**  **0 0**  **0 0**  **536 0**  **0 0**  **0 0**  **5900 0**  **0 0**  **0 0**  **932 0**  **0 0**  **0 0**  **68 205**  **137 342**  **137 68**  **0 0**  **0 617**  **0 0**  **4 0**  **0 0**  **0 0**  **0 1**  **0 0**  **0 0**  **40 7**  **0 13**  **0 0**  **174 522**  **348 870**  **348 174**  **0 99**  **7 0**  **0 0**  **83720 0**  **0 0**  **0 0**  **Total pounds of HAPs**

**94559 2055**  **1022 1842**  **511 242**  **3830**

Note: all glaze spray booths have dust collector systems that have a minimum capture ratio of 90%. This would put our HAP emissions at 383 lbs maximum. **We have not tracked Glaze usage in the past on a consistant basis as there is no requirement to do so in our permit. (We do not have HAPs in our glaze in appreciable amounts).** 
**The following is the total amounts of all metals in our glazes in pounds.**

**Please note that the vast majority of these are used in our Roto color machines which are not a spray application.**  ****Note: decorating lines #6 and #7 feed Kiln # 6. No separate times are available for each line. Note: Kiln #2, while still on the permit, has not been run since 2005. It is currently being used for spare**  **parts. The decorating line is occassionally used with he feed going to Kiln #1.** FACILITY and GLAZE LINE IDs

**(a) A "HAP containing glaze" is any glaze that contains a material or ingredient listed as a metal HAP on the MSDS for that glaze/material.** PLANTWIDE GLAZE USE

EPA-HQ-OAR-2013-0290-DRAFT-0016 FORM C - Glaze Line Info 12/1/2014**INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY**  **FORM D - KILN APCD INFORMATION**

APCD Information BAGHOUSE/FABRIC FILTER (Stand-alone or as part of DIFF or DLS)

Facility ID Kiln ID(s) [Use the ID

from your permit or assign using TK-1, 2, etc for tunnel, RK-1, 2, etc for roller, and PK-1, 2, etc for periodic] Stack Diameter (ft) Control ID # (assign based on ID used in Title V or using CD-1, 2, etc) Type Reason Control was Installed Number of kilns

vented to this control device Year control device

was installed Total bag surface

area (ft2) Bag- material of

construction Avg Life of bags

(yrs) Air-to-Cloth Ratio

(see instructions)Cleaning method Line #1 Kiln n/a Line #2 Kiln n/a Line #5 Kiln n/a Line #6 Kiln n/a FACILITY and KILN IDs

EPA-HQ-OAR-2013-0290-DRAFT-0016 FORM D - Kiln APCD Info 12/1/2014**INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY**  **FORM D - KILN APCD INFORMATION**

Facility ID Kiln ID(s) [Use the ID

from your permit or assign using TK-1, 2, etc for tunnel, RK-1, 2, etc for roller, and PK-1, 2, etc for periodic] Line #1 Kiln Line #2 Kiln Line #5 Kiln Line #6 Kiln FACILITY and KILN IDs DLS or DIFF DLA

Reagent TypeReagent feedrate

(value) Units/ time Total annual reagent usage (indicate units) Is reagent

recirculated or one-pass? If recirculated,

average ratio of recirculated to fresh reagent Number of

cascades Do you use

reconditioning drum/peeler?What is the rate

at which limestone is removed from the system as waste? Parameter

monitored Monitoring

frequency Type of scrubber

(e.g., venturi) Liquid flow rate

(gal/min)

EPA-HQ-OAR-2013-0290-DRAFT-0016 FORM D - Kiln APCD Info 12/1/2014**INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY**  **FORM D - KILN APCD INFORMATION**

Facility ID Kiln ID(s) [Use the ID

from your permit or assign using TK-1, 2, etc for tunnel, RK-1, 2, etc for roller, and PK-1, 2, etc for periodic] Line #1 Kiln Line #2 Kiln Line #5 Kiln Line #6 Kiln FACILITY and KILN IDs OTHER CONTROL (please identify parameters and units monitored to verify control is functioning properly)

Pressure drop across scrubber (inches of water) pH range of

scrubbing liquidReagents used to

maintain pH in desired range Total annual

reagent usage (indicate units) Units / Time Design or Monitoring Parameter Units / Time Design or Monitoring Parameter Units / Time Design or Monitoring Parameter Units / Time

EPA-HQ-OAR-2013-0290-DRAFT-0016 FORM D - Kiln APCD Info 12/1/2014

### INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY **INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY FORM E - GLAZE LINE APCD INFORMATION**  FACILITY and GLAZE LINE IDs CONTROL DEVICE INFORMATION BAGHOUSE/FABRIC FILTER WET SCRUBBER

Facility ID Glaze Line ID(s) [Use

the ID from your permit or assign using GZ-1, 2, etc] Control ID # (assign

based on ID used in Title V or using CD-1, 2, etc) Type Reason Control was Installed Number of spray

booths vented to this control device Year control

device was installed Total bag surface

area (ft2

### ) Bag- material of

construction Avg Life of bags

(yrs) Cleaning methodType of scrubber (e.g., venturi) Liquid flow rate

(gal/min)

Decorating Line #1 Water curtain Particulate/ opac. control 1 1997

Decorating Line #2 Water curtain Particulate/ opac. control 1 1997

Decorating Line #5 Water curtain Particulate/ opac. control 1 1997

Decorating Line #6 Fabric filter Particulate/ opac. control 17 2006

Decorating Line #7 Fabric filter Particulate/ opac. control 17 2006

EPA-HQ-OAR-2013-0290-DRAFT-0016 FORM E - Glaze Line APCD Info 12/1/2014

### INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY **INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY FORM E - GLAZE LINE APCD INFORMATION**  FACILITY and GLAZE LINE IDs

Facility ID Glaze Line ID(s) [Use

the ID from your permit or assign using GZ-1, 2, etc]

Decorating Line #1

Decorating Line #2

Decorating Line #5

Decorating Line #6

Decorating Line #7 WATER CURTAIN OTHER CONTROL (please identify parameters and units monitored to verify control is functioning properly)

Pressure drop across scrubber (inches of water)Water flow rate

(gal/min) Width of water

curtain (ft) Equipped with

baffle or mist eliminator? Design or

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

EPA-HQ-OAR-2013-0290-DRAFT-0016 FORM E - Glaze Line APCD Info 12/1/2014**INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY**

**FORM F - TEST DATA**

GENERAL INFORMATION TEST INFORMATION ADDITIONAL INFORMATION

FAC ID Control ID Kiln/Glaze Line/ Stack ID Test Date Report Date Type of TestUncontrolled (or inlet to control), Controlled, Both HF HCl PM HAP Metals Other (list below) Other (list

below) Other (list

below) Reasons for Test APCD Parameters Monitored During Test Notes

Line 6 Kiln15,16 Jan 2008 20-Feb-08 X X Compliance verifcation N/A Full test Included

**Other Tests CO** POLLUTANTS TESTED (Please put X in box to indicate pollutant was tested)



### Please provide copies of full test reports to minimize the need for future information requests. Field notes and raw reading sections can be omitted. However, please include all other sections of the reports, including sample calculations, laboratory data, run-by-run emission data, and a description of any deviations from test methods or other anomalies that occurred with the process or control device operations during the test. Please also provide information on the following for each test: production rate in units of fired product (tph); APCD parameters monitored and monitored values; and any anecdotal information you believe would potentially be helpful to us.

EPA-HQ-OAR-2013-0290-DRAFT-0016 FORM F - Test Data 12/1/2014**INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY FORM G - MONITORING AND OTHER COSTS** 
**Facility ID** Florida Tile

**Unit Costs for January 2008**

Parameter Cost Electricity cost, $/kwh Deleted as CBI Reagent: Reagent Cost, $/ton Waste Reagent disposal cost, $/ton or $/year Water treatment costs, $/gal Deleted as CBI

Activity Required by Activity Estimated Hours Frequency Staff Level Deleted as CBI Deleted as CBI Deleted as CBIDeleted as CBI

Deleted as CBI Deleted as CBI Deleted as CBIDeleted as CBI

Deleted as CBI Deleted as CBI Deleted as CBIDeleted as CBI Deleted as CBI Deleted as CBI Maintain free-flowing lime (Describe action in next box and then add estimated hours, frequency, and staff level) 

## N/A N/A N/A N/A

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

approach 

## N/A N/A N/A N/A

Control Device: baghouse Deleted as CBI Deleted as CBI Deleted as CBIDeleted as CBI Deleted as CBI Deleted as CBI Deleted as CBIDeleted as CBI Deleted as CBI

Deleted as CBI Deleted as CBI Deleted as CBIDeleted as CBI Deleted as CBI Deleted as CBI Deleted as CBIDeleted as CBI

Deleted as CBI Deleted as CBI Deleted as CBI Deleted as CBI Deleted as CBI Deleted as CBI Deleted as CBIDeleted as CBI Deleted as CBI Deleted as CBI Deleted as CBIDeleted as CBI

Deleted as CBI Deleted as CBI Deleted as CBI Deleted as CBI

Stack Test Costs for the Previous 3 Years

Stack Test Year Test Methods (please list alltest methods conducted during stack test) Uncontrolled (include uncontrolled stack or APCD inlet)? Controlled? Both?Cost ($) Notes (Include Any site/preparation costs not included in estimate) 2008 methods 1-4,10, and 26 Uncontrolled Deleted as CBI Deleted as CBI

Below is a chart with all data we have on our duct collectors

Dia Length No Bag Bags BagsAir CapacityComments Desig. Mfg Bags $ in. ft MC/H **Mill Room** ??? Pneumafil 160 5.80 4.625 10.00 ???

**Old BP** 4A Mikropul 288 8.82 4.625 8.3327,184 - 34,582 4B Pneumafil 316 5.80 4.625 10.0055,217 - 67,960 4C Mikropul 288 60.00 4.875 6.7732,281 - 33,980 paper, pleated bag @26.3 ft2

**New BP** DC-74 Sacmi 264 22.40 5.000 8.33 18,000 DC-75 Sacmi 936 22.40 5.000 8.33 ???
**Raw Material Building** DC-73 Carter Day 124 8.82 4.500 8 36,393bag price is an estimate
**Porcelain Glazing Line Line 6**  Pneumafil 256 9.25 4.500 10 48,237

**Wa ll Glazing Lines**  **Lines 1,2,and 5** hydro-filter ???

- - - - ??? 

### PLA**NT DUST COLLECTORS** Please also provide separately an itemized list of site/preparation costs not included in the estimate (e.g., costs for drilling ports in stack, costs for installing permanent access to sampling ports, etc.) Standard Activities- DLA (limestone) Deleted as CBI

Deleted as CBI Standard Activities- Wet Scrubber or Other Control

EPA-HQ-OAR-2013-0290-DRAFT-0016 FORM G - Monit-Other Costs 12/1/2014

## INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY

**FORM H - ECONOMICS IMPACTS INFORMATION**

Product Selling Price Labor Rates as of January 2008

Facility ID Product type Average Selling Price per Ton ($) Reporting Year for

Selling Price (if not 2007) Operator wage

rate, $/hr Maintenance wage

rate, $/hr Engineer wage

rate, $/hr Managerial/Supervisory

wage rate, $/hr 2100500008 Deleted as CBI Deleted as CBI Deleted as CBIDeleted as CBI Deleted as CBI Deleted as CBI Deleted as CBIDeleted as CBI Deleted as CBI Deleted as CBI Deleted as CBIDeleted as CBI

We do not track the selling price by product that is made in our facility. We sell a large variety of products with a substantial number of them imprted and resold on the domestic market. The selling price is exceptionally varied. We also sell some of the same items at retail and wholesale.

EPA-HQ-OAR-2013-0290-DRAFT-0016 Form H - Economics Info 12/1/2014

# INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY **FORM I - ADDITIONAL QUESTIONS** Question Response
1. Please provide a copy of the cost estimate for your selected control device and explain any differences between the estimated and final installed costs. Costs should include costs for ancillary equipment, such as reconditioning drums, water treatment systems, etc N/A 2. Do you currently do any work or operating practices (i.e., other than the use of an air pollution control device) that would have an impact on HF, HCl, or PM emissions from your kilns? If yes, please explain. No 3. If you operate periodic kilns, please provide a time-temperature profile for each typical batch cycle. The profiles should show the duration of each temperature phase of the cycle from the time the kiln is fired to the time when the fired shapes can be removed from the kiln. (See instructions for example profile.) N/A 4. If you operate periodic kilns, do you have any information regarding technological and/or economic limitations to testing those kilns? N/A 5. Please provide a copy of a process flow diagram for your facility, if available. See Attached

EPA-HQ-OAR-2013-0290-DRAFT-0016 FORM I - Additional Questions 12/1/2014