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)

1 ES-K1 Tunnel 1995 4 brick 8760 Yes 8 8 100 Natural gas None n/a

1 ES-K2 Tunnel 2000 4 brick 8760 Yes 8 8 100 Natural gas None n/a

1 ES-K3 Periodic-shuttle 1 2002 6 brick 3000 No 2 2 70 Natural gas None n/a

1 ES-K4 Tunnel 2006 3 brick 8760 Yes 8 8 100 Natural 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

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

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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]

1 ES-K1

1 ES-K2

1 ES-K3

1 ES-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 0 No

None n/a 0 No

None n/a 0 No 72 36 100 2 2

None n/a 0 No

FUEL USAGE FOR SAWDUST FIRED KILNS ONLY

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

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

1 ES-K2 CD-1

Dry Limestone Adsorber 

(DLA) Other 2 1999 limestone 56 lbs/hr 40

1 ES-K4 CD-2 Wet Scrubber

Become Synthetic 

Minor 1 2006 lime slurry 0.8 gal/min 30 1000

DESIGN AND OPERATING PARAMETERS

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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]

1 ES-K1

1 ES-K2

1 ES-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

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

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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]

1 ES-K1

1 ES-K2

1 ES-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

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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 4 yearly Manager

Develop and implement an operating, 

maintenance, and monitoring plan Develop plan and educate staff 8 yearly Manager

Bag replacement Replace single bag 1 as needed Maintenance

Bag replacement Replace all bags 20 2 years Maintenance

Maintain free-flowing lime (Describe action 

in next box and then add estimated hours, 

frequency, and staff level) monitor systems 2 daily 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 2 daily 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 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)

2007 see 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

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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

1 brick $120.00 9 15 25 20

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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.

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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