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

**FORM A - GENERAL INFORMATION**

**Parent Company Information** Parent Company Taylor Clay Products, Inc 

### Street Address- Line 1 185 Peeler Road 

### Street Address- Line 2 City Salisbury 

### State NC 

### Zip code 28146 

### Mailing Address (if different)- Line 1 P O Box 2128 

### Mailing Address (if different)- Line 2 City Salisbury 

### State NC 

### Zip code 28145 

### Number of Employees in Parent Company 0-99 

### Dun and Bradstreet number

**Facility Information**

Facility 1 Facility 2 Facility 3 Facility 4 Facility 5 Facility 6 Facility 7 Facility ID Facility Name Taylor Clay Address 1 185 Peeler Road Address 2 City Salisbury County Rowan State NC Zip code 28146 Mailing Address (if different)- Line 1 P O Box 2128 Mailing Address (if different)- Line 2 City Salisbury State NC Zip code 28145 Number of employees at facility 0-99 What is your size classification for HAP emissions? Area Source (synthetic) Hours of operation for this facility (hr/yr) 8780 Facility's primary NAICS or SIC code 3251 Total Number of Periodic Kilns at this Facility 1 Total Number of Tunnel Kilns at this Facility 3 Contact Person for this ICR Steven Blankenbeker Contact Phone Number (704)636-2411 Contact Email Address s_blankenbeker@yahoo.com

090000648192f208 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)
1ES-K1 Tunnel 1995 4brick 8760Yes 8 8 100Natural gas None n/a 1ES-K2 Tunnel 2000 4brick 8760Yes 8 8 100Natural gas None n/a 1ES-K3 Periodic-shuttle 1 2002 6brick 3000No 2 2 70Natural gas None n/a 1ES-K4 Tunnel 2006 3brick 8760Yes 8 8 100Natural gas Other 10

**(a)**Kiln size capacities should be in units of tons per hour (tph) of fired product

Brick & Pipe
Brick Brick Pavers Clay Pipe/Flue Liners etc. Clay Roofing Tile Common Brick Face Brick Fire Brick Fired Clay or Shale Brick Flashed Product (fuel flashed) Floor Tile Reduction Fired Products Special Shapes Structual Tile Structural Brick Thin Brick Types of products For this question, indicate the general types of products that are made in the kiln, particularly if products other than standard or king brick are frequently made and if the type of product significantly impacts processing or production rate . Some example products are listed below. Use others, if necessary FUEL USAGE KILN SIZE**(a)** FACILITY and KILN IDs GENERAL INFORMATION

090000648192f208 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]
1ES-K1 1ES-K2 1ES-K3 1ES-K4

**(a)**Kiln size capacities should be in units of tons per hour (tph) of fired product

Brick & Pipe
Brick Brick Pavers Clay Pipe/Flue Liners etc. Clay Roofing Tile Common Brick Face Brick Fire Brick Fired Clay or Shale Brick Flashed Product (fuel flashed) Floor Tile Reduction Fired Products Special Shapes Structual Tile Structural Brick Thin Brick Types of products For this question, indicate the general types of products that are made in the kiln, particularly if products other than standard or king brick are frequently made and if the type of product significantly impacts processing or production rate . Some example products are listed below. Use others, if necessary FACILITY and KILN IDs ADDITIONAL INFORMATION ON PERIODIC KILNS

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 n/a 0No None n/a 0No None n/a 0No 72 36 100 2 2 None n/a 0No FOR SAWDUST FIRED KILNS ONLY FUEL USAGE

090000648192f208 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
1ES-K1 CD-1 (DLA) Other 2 1999 limestone 56 lbs/hr 40

1ES-K2 CD-1 Dry Limestone Adsorber (DLA) Other 2 1999 limestone 56 lbs/hr 40

1ES-K4 CD-2 Wet Scrubber Become Synthetic Minor 1 2006 lime slurry 0.8 gal/min 30 1000 DESIGN AND OPERATING PARAMETERS

090000648192f208 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]
1ES-K1

1ES-K2

1ES-K4 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? n/a One pass 7 No 56 /bs/hr

n/a One pass 7 No 56 lbs/hr

182 10 0.42 0.42 fibre glass/teflon 1.5 pulse air 4.46:1 $10,000.00 12,488 One pass n/a No DLA DIFF or DLS BAGHOUSE/FABRIC FILTER (Stand-alone or as Part of DLS/DIFF system)

090000648192f208 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]
1ES-K1

1ES-K2

1ES-K4 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

wet lime slurry injection 0.8 gal/min 3.7 fan speed 45 Hz air to nozzle 85 psi Slurry pump 16 Hz DLA

090000648192f208 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 1 ES-K4 EP-CD-3 11/1/2007 Both x x x sulfur Prove new scrubber see results 8 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.

090000648192f208 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**

**Unit Costs for January 2008**

Parameter Cost Electricity cost, $/kwh $0.05 Reagent: Reagent Cost, $/ton $136.00 Waste Reagent disposal cost, $/ton $30.00 Water treatment costs, $/gal 0

Activity Required by Activity Estimated Hours Frequency Staff Level Develop a start-up, shutdown, and malfunction plan Develop plan and educate staff 4yearly Manager Develop and implement an operating, maintenance, and monitoring plan Develop plan and educate staff 8yearly Manager

Bag replacement Replace single bag 1as needed Maintenance Bag replacement Replace all bags 202 years Maintenance

Maintain free-flowing lime (Describe action in next box and then add estimated hours, frequency, and staff level) monitor systems 2daily Operator

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 monitor systems 2daily Operator

Control Device: Compliance demonstration activity (describe and estimate hours, frequency, and staff level) wet scrubber 2 monthly Maintenance Compliance demonstration activity (describe and estimate hours, frequency, and staff level) Compliance demonstration activity (describe and estimate hours, frequency, and staff level)
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)

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)
2007see results Both 25,000

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) Standard Activities- Baghouse/DIFF/DLS

Standard Activities- All Controls Standard Activities- Wet Scrubber or Other Control

090000648192f208 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 1brick $120.00 9 15 25 20

090000648192f208 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 Our wet scrubber is a new prototype manufactured by StaClean. Because the development and installation was all new, there was not a purchase order in the normal sense. They have an interest in selling these scrubbers to the brick industry, and used this installation in part as a trial. Our initial estimation for the scrubber was about $700,000.00, and we ended up going over this by about $150,000.00. 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. 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. no 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. n/a

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.0:00 - 1:00 load, 1:00 - 8:00 100 - 1200 degrees F, 8:00 - 9:00 1200 - 1300 degrees F, 9:00 - 20:00 1300 - 2100 degrees F, 2100 - 46:00 2100 - 100 degrees

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.

090000648192f208 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