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

FORM A - GENERAL INFORMATION

Parent Company Information

Parent Company Boral Bricks Inc.

Street Address- Line 1 200 Mansell Court East

Street Address- Line 2 Suite 305

City Roswell

State GA

Zip code 30076

Mailing Address (if different)- Line 1

Mailing Address (if different)- Line 2

City

State

Zip code

Number of Employees in Parent Company >500

Dun and Bradstreet number 003275682

Facility Information

Facility 1 Facility 2 Facility 3 Facility 4 Facility 5 Facility 6 Facility 7 Facility 8 Facility 9 Facility 10 Facility 11 Facility 12

Facility ID BORA-1 BORA-2 BORA-3 BORA-4 BORA-5 BORA-6 BORA-7 BORA-8 BORA-9 BORA-10 BORA-11 BORA-12

Facility Name Boral- Atlanta Plant Boral- Augusta Plant 6 Boral- Augusta Plants 3, 4, & 

5

Boral- Bessemer Plant #5 Boral- Bessemer Plant #6 Boral- Gleason Plant Boral- Henderson Facility Boral- Ione Plant Boral- Lexington Plant Boral- Macon, GA Plant Boral- Macon, MS Plant Boral- Marshall Plant

Address 1 5472 Oakdale Road 1449 Doug Barnard Prkwy 1630 Athern Road 5501 Vulcan Road 8250 Hopewell Rd. S.E. Old Highway 22 1309 Kilgore Drive 1000 King Street Station Hwy 1 and Brickyard Road 711 10th Street 14404 Highway 14 1902 N. Franklin Street

Address 2

City Smyrna Augusta Augusta Bessemer Bessemer Gleason Henderson Amador Lexington Macon Macon Marshall

County Cobb Richmond Richmond Jefferson Jefferson Weakley Rusk Ione Lexington Bibb Noxubee Harrison

State GA GA GA AL AL TN TX CA SC GA MS TX

Zip code 30082 31208 30901 35022 35022 38229 75653 95640 29072 31208 39341 75670

Mailing Address (if different)- Line 1 P.O. Box 517 P.O. Box 517 PO Box 72 P O Box 1550 PO Box 868

Mailing Address (if different)- Line 2

City Bessemer Bessemer Gleason Ione

State Alabama Alabama TN CA

Zip code 35021 35021 38229 95640

Number of employees at facility 39 33 94 63 66 45 74 50 42 40 75 35

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

Hours of operation for this facility (hr/yr) (CY07) 8760 8424 8760 8760 8016 8760 8760 0* 0** 8016 8760 8760

Facility's primary NAICS or SIC code 3251 3251 3251 3251 3251 3251 3251 3251 3251 3251 3251 3251

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

Total Number of Tunnel Kilns at this Facility 2 2 4 2 2 2 2 1 1 1 2 1

Contact Person for this ICR Terry Schimmel Terry Schimmel Terry Schimmel Terry Schimmel Terry Schimmel Terry Schimmel Terry Schimmel Mary Ann Keon Terry Schimmel Terry Schimmel Terry Schimmel Terry Schimmel

Contact Phone Number 334-480-2488 334-480-2488 334-480-2488 334-480-2488 334-480-2488 334-480-2488 334-480-2488 770--645-4529 334-480-2488 334-480-2488 334-480-2488 334-480-2488

Contact Email Address terry.schimmel@boral.com terry.schimmel@boral.com terry.schimmel@boral.com terry.schimmel@boral.com terry.schimmel@boral.com terry.schimmel@boral.com terry.schimmel@boral.com maryann.keon@boral.com terry.schimmel@boral.com terry.schimmel@boral.com terry.schimmel@boral.com terry.schimmel@boral.com

*Plant started operations in 

2008

**Down due to business 

comditions

090000648192f15d

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) (CY07)

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 13 Facility 14 Facility 15 Facility 16 Facility 17 Facility 18 Facility 19 Facility 20 Facility 21

BORA-13 BORA-14 BORA-15 BORA-16 BORA-17 BORA-18 BORA-19 BORA-20 BORA-21

Boral- Muskogee Plant Boral- Phenix City-Plant 3 Boral- Phenix City-Plant 4 Boral- Phenix City-Plants 1 & 

2

Boral- Salisbury Plant Boral- Terre Haute Plant Boral- Union City Plant Boral- United States Tile Boral- Van Wyck Plants

3101 West 53rd Street S. 100 Brickyard Road 100 Brickyard Road 100 Brickyard Road 700 North Long Street 5601 East Price Drive 3895 South Choctaw St. 909 West Railroad Street 7472 Van Wyck Road

Muskogee Phenix City Phenix City Phenix City Salisbury Terre Haute Union City Corona Van Wyck

Muskagee Russell Russell Russell Rowan Vigo Canadian Riverside Lancaster

OK AL AL AL NC IN OK CA SC

74401 36865 36865 38665 28145 47802 73090 91720 29744

P.O. Box 1178 P.O. Box 1178 P.O. Box 1178 PO Box 99

Columbus Columbus Columbus

GA GA GA

31902 31902 31902

53 36 65 52 145 42 45 125 81

Major source Major source Major source Major source Major source Major source Area Source (synthetic) Area Source (true) Major source

8256 8544 8760 0** 8760 0* 8760 8760 7752

3251 3251 3251 3251 3251 3251 3251 3251 3251

0 0 0 0 0 0 0 1 0

1 2 3 1 2 1 1 2 2

Terry Schimmel Terry Schimmel Terry Schimmel Terry Schimmel Terry Schimmel Terry Schimmel Terry Schimmel Mary Ann Keon Terry Schimmel

334-480-2488 334-480-2488 334-480-2488 334-480-2488 334-480-2488 334-480-2488 334-480-2488 770--645-4529 334-480-2488

terry.schimmel@boral.com terry.schimmel@boral.com terry.schimmel@boral.com terry.schimmel@boral.com terry.schimmel@boral.com terry.schimmel@boral.com terry.schimmel@boral.com maryann.keon@boral.com terry.schimmel@boral.com

**Down due to business 

comditions

*Plant started operations in 

2008

090000648192f15d

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 

PK-1,2, 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)

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

BORA-1 EU01 Tunnel 1971 5.48 Brick & Special Shapes 4560 Yes 14.97 N/A 32.5% Natural gas None N/A Propane Curtailment 0 No

BORA-1 EU02 Tunnel 1971

Combined 

with above Brick & Special Shapes 7968 Yes 14.97 N/A 56.8% Natural gas None N/A Propane Curtailment 0 No

BORA-2 EU02 Tunnel 1970 3.4 Brick & Special Shapes 8424 No 11.25 9.99 69.9% Natural gas None N/A Propane Curtailment 0 No

BORA-2 EU03 Tunnel 1970 3.4 Brick & Special Shapes 8064 No 11.25 9.99 66.9% Natural gas None N/A Propane Curtailment 0 No

BORA-3 EU01 Tunnel

1962 

Rebuilt 

1999 3.1 Brick & Special Shapes 0 No 11.3 9.99 0.0% Natural gas None N/A Propane Curtailment 0 No

BORA-3 EU02 Tunnel 1962 3.1 Brick & Special Shapes 1992 No 11.3 9.99 16.9% Natural gas None N/A Propane Curtailment 0 No

BORA-3 EU05 Tunnel 1978 6.0 Brick & Special Shapes 6312 Yes 22.2 N/A 40.9% Sawdust Natural gas 100 Propane Curtailment 0 No

BORA-3 EU41 Tunnel

Rebuilt 

1999 4.94

Brick Pavers (primarily) 

& Special Shapes & 

Brick 8760 Yes 19.6 N/A 41.9% Natural gas None N/A Propane Curtailment 0 No

BORA-4 003 Tunnel 1965 3.3 Brick & Special Shapes 8760 No 12 9.99 83.0% Natural gas None N/A Propane Curtailment 8 No

BORA-4 004 Tunnel 1966 3.3 Brick & Special Shapes 7608 No 12 9.99 72.0% Natural gas None N/A Propane Curtailment 8 No

BORA-5 003 Tunnel 1989 5.83 Brick & Special Shapes 8016 Yes 12.51 N/A 67.4% Natural gas None N/A Propane Curtailment 0 No

BORA-5 004 Tunnel 1989

Combined 

with above Brick & Special Shapes 8016 Yes 12.51 N/A 67.4% Natural gas None N/A Propane Curtailment 0 No

BORA-6 ES02 Tunnel 1960 3.125 Brick & Special Shapes 8760 No 9.8 9.82 49.5% Natural gas None N/A None N/A N/A No

BORA-6 ES03 Tunnel 1964 3.0 Brick & Special Shapes 8760 No 9.8 9.82 49.5% Natural gas None N/A None N/A N/A No

BORA-7 K-1 Tunnel 1961 5.95 Brick 8760 Yes 11.33 11.13 83.9% Natural gas None N/A None N/A N/A No

BORA-7 K-2 Tunnel 1962

Combined 

with above Brick 8760 Yes 11.33 11.13 83.9% Natural gas None N/A None N/A N/A No

BORA-8 TK1

Tunnel- low 

profile or roller 2008 3 Clay Roofing Tile 0 No 12.2 12.2 0.0% Natural gas None N/A Propane Curtailment 0 No

BORA-9 EU01 Tunnel 1980 4.0 Brick & Special Shapes 0 No 12.25 9.99 0.0% Natural gas None N/A Propane Curtailment 0 No

BORA-10 EU01 Tunnel 1979 3.33 Brick & Special Shapes 8016 No 12.7 9.99 49.1% Natural gas None N/A Propane Curtailment 0 No

BORA-11 AA-001 Tunnel 1994 3.2 Brick & Special Shapes 8760 No 10.1 9.99 64.1% Natural gas None N/A None N/A N/A No

BORA-11 AA-002 Tunnel 1994 3.2 Brick & Special Shapes 8760 No 10.1 9.99 64.1% Natural gas None N/A None N/A N/A No

BORA-12 KLN Tunnel 1983 2.42 Brick 8760 No 8.38 6.7 82.9% Natural gas None N/A None N/A N/A No

BORA-13 EU-04 Tunnel 1980 6.21 Brick 8256 Yes 23.43 N/A 77.7% Natural gas None N/A None N/A N/A No

BORA-14 TK-1 Tunnel 1956 2.67 Brick & Special Shapes 8136 No 10 9.99 51.6% Natural gas None N/A Propane Curtailment 0 No

BORA-14 TK-1 Tunnel 1959 2.67 Brick & Special Shapes 7080 No 10 9.99 44.9% Natural gas None N/A Propane Curtailment 0 No

BORA-15 TK41-1 Tunnel 1980 3 Brick & Special Shapes 5664 No 13.5 9.99 28.9% Natural gas None N/A Propane Curtailment 0 No

BORA-15 TK42-1 Tunnel 1956 3.18 Brick & Special Shapes 8760 No 11.2 9.99 50.4% Natural gas None N/A Propane Curtailment 0 No

BORA-15 TK42-2 Tunnel 1959 3.18 Brick & Special Shapes 6744 No 11.2 9.99 38.8% Natural gas None N/A Propane Curtailment 0 No

BORA-16 tk-1 Tunnel 1974 4.16 Brick & Special Shapes 0 No 16 9.99 0.0% Natural gas None N/A Propane Curtailment 0 No

BORA-17 5BK Tunnel 1954 3.39 Brick & Special Shapes 7264 No 10.7 9.99 48.2% Sawdust Natural gas <1% None N/A N/A No

BORA-17 6BK Tunnel 1965 6.25 Brick & Special Shapes 8760 Yes 27.8 N/A 66.3% Sawdust Natural gas 10% None N/A N/A Yes

5RWD & 

6RWD 1 65% 25%

BORA-18 EU02 Tunnel 2008 5.90 Brick & Special Shapes 0 Yes 26 N/A 0.0% Landfill/ Biogas Natural gas 20% Natural gas

Primary fuel 

shortage 0 No

BORA-19 EU02 Tunnel 2005 4.5 Brick 8760 Yes 19.4 N/A 99.7% Natural gas Landfilll/ Biogas 34% None N/A 0 No

BORA-20 D154

Tunnel- low 

profile or roller

Rebuilt 

2005 3 Clay Roofing Tile 8760 No 10.6

MMBTU & 

NOx limits 

only 89.0% Natural gas None 0 None N/A 0 No

BORA-20 D76

Tunnel- low 

profile or roller 1989 2.5 Clay Roofing Tile 8016 No 7.1

MMBTU & 

NOx limits 

only 86.5% Natural gas None 0 None N/A 0 No

BORA-20 D159

Tunnel- low 

profile or roller 1

Rebuilt 

2006 3 Clay Roofing Tile 2772 No 0.5 

MMBTU & 

NOx limits 

only 11.8% Natural gas None 0 None N/A 0 No

BORA-21 EU03 Tunnel 1988 5.5 Brick & Special Shapes 7752 No 9.73 9.99 69.9% Natural gas None N/A Propane Curtailment 0 No

BORA-21 EU09 Tunnel 1978

Combined 

with above Brick & Special Shapes 7752 No 12.73 9.99 56.3% Natural gas None N/A Propane Curtailment 0 No

FACILITY and KILN IDs GENERAL INFORMATION KILN SIZE (a) FUEL USAGE FOR SAWDUST FIRED KILNS ONLY

090000648192f15d

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 

PK-1,2, etc for 

periodic]

BORA-1 EU01

BORA-1 EU02

BORA-2 EU02

BORA-2 EU03

BORA-3 EU01

BORA-3 EU02

BORA-3 EU05

BORA-3 EU41

BORA-4 003

BORA-4 004

BORA-5 003

BORA-5 004

BORA-6 ES02

BORA-6 ES03

BORA-7 K-1

BORA-7 K-2

BORA-8 TK1

BORA-9 EU01

BORA-10 EU01

BORA-11 AA-001

BORA-11 AA-002

BORA-12 KLN

BORA-13 EU-04

BORA-14 TK-1

BORA-14 TK-1

BORA-15 TK41-1

BORA-15 TK42-1

BORA-15 TK42-2

BORA-16 tk-1

BORA-17 5BK

BORA-17 6BK

BORA-18 EU02

BORA-19 EU02

BORA-20 D154

BORA-20 D76

BORA-20 D159

BORA-21 EU03

BORA-21 EU09

FACILITY and KILN IDs

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)

ADDITIONAL INFORMATION ON PERIODIC KILNS

090000648192f15d

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

BORA-1 EU01 &EU02 DFF1

Dry Injection/Fabric Filter 

(DIFF)

Comply with 

MACT 2 2006 Hydrated lime 66 lbs/hr 250 30 0 Not available Compressed Air

32 scfm @ 100 

psi

BORA-13 EU-04 CD1

Dry Injection/Fabric Filter 

(DIFF)

Comply with 

MACT 1 2007 Hydrated lime 214 lbs/hr 150 51 0 30000 Compressed Air

90 scfm @ 100 

psi

BORA-17 BK6 DIFF1

Dry Injection/Fabric Filter 

(DIFF)

Comply with 

MACT 1 2007 Hydrated lime 185 lbs/hr 300 30 0 4700 Compressed Air

50 scfm @ 100 

psi

BORA-18 EU02 CD01

Dry Injection/Fabric Filter 

(DIFF)

Comply with 

MACT 1 2008 Hydrated lime 86 lbs/hr 268 40 0 Varies Compressed Air

60 scfm @ 100 

psi

BORA-19 EU04 CD01

Dry Injection/Fabric Filter 

(DIFF)

Become Synthetic 

Minor 1 2006 Hydrated lime 36 lbs/hr 200 7 0 Unknown Compressed Air

60 scfm @ 100 

psi

BORA-3 EU41 CE41

Dry Injection/Fabric Filter 

(DIFF) Other 1 2001 Hydrated lime 15.6 lbs/hr 200 40 0 ? Compressed Air

Approx 75 scfm 

@ 100 psi

BORA-3 EU05 DIFF

Dry Injection/Fabric Filter 

(DIFF)

Comply with 

MACT 1 2006 Hydrated lime 143 lbs/hr 350 80 0 Varies Compressed Air

120 scfm @ 102 

psi

BORA-5 003, 004 CD-1

Dry Injection/Fabric Filter 

(DIFF)

Comply with 

MACT 2 2007 Hydrated lime 140 lbs/hr 300 30 0 3500 Compressed Air

50 scfm @ 100 

psi

BORA-7 K-1, K-2 da-1

Dry Limestone Scrubber 

(DLA) Other 2 1993 Limestone 0.1 tph 75 19 0 0 Blower

Blower fan motor 

operates at 2850 

rpm

DESIGN AND OPERATING PARAMETERS

090000648192f15d

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]

BORA-1 EU01 &EU02

BORA-13 EU-04

BORA-17 BK6

BORA-18 EU02

BORA-19 EU04

BORA-3 EU41

BORA-3 EU05

BORA-5 003, 004

BORA-7 K-1, K-2

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?

1024 19 N/A 0.5 PTFE

Not yet 

determined Air pulse 2.61:1 $ 104,000 32 scfm One pass N/A

1088 22 N/A 0.5 PTFE

Not yet 

determined Air pulse 2.57:1 $ 114,000 65 One pass N/A

920 18 N/A 0.5 PTFE

Not yet 

determined Air pulse 3.28:1 $ 225,000 80 - 120 One pass

Designed as 

recirculation but 

not used

392 16.5 N/A 0.5 PTFE

Not yet 

determined Air pulse 3.25:1 $ 85,000 

60 scfm @ 100 

psi Recirculated 10:1

816 19 N/A 0.5 PTFE

Not yet 

determined Air pulse 2.7:1 $ 81,000 

60 scfm @ 100 

psi One pass N/A

672 16 N/A 0.5 Felt Nomex >5 yrs Air pulse 3.5:1 $ 50,000 

Apprx. 90 scfm @ 

100 psi One pass N/A

1176 16.5 N/A 0.5 PTFE

Not yet 

determined Air pulse 3.22:1 $ 250,000 

110 scfm @ 100 

psi Recirculated 10:1

880 18 N/A 0.5 PTFE

Not yet 

determined Air pulse 2.49:1 $ 211,200 

90 scfm @ 100 

psi Recirculated 0.3:1

0 N/A N/A N/A N/A N/A N/A N/A N/A N/A Approx. 200 Yes 75 tons/month

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

090000648192f15d

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]

BORA-1 EU01 &EU02

BORA-13 EU-04

BORA-17 BK6

BORA-18 EU02

BORA-19 EU04

BORA-3 EU41

BORA-3 EU05

BORA-5 003, 004

BORA-7 K-1, K-2

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

Pressure Drop

Daily climb to 

hopper

For compliance 

w/ State issued 

permit

DLA

090000648192f15d

FORM C - APCD Info 11/17/2014
Note this list does not repeat test reports submitted as part of EPA's previous data gathering efforts in 1998

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

BORA-1

EU01, 

EU02 11/2/2004 Nov-04 Uncontrolled X x X

Hydrocarbons, 

Nox, SO2 12.66

BORA-1

EU01, 

EU02 2/8/2005 2/8-9/2006 Uncontrolled X x X

Hydrocarbons, 

Nox, Methane 12.29

BORA-1 DFF1

EU01 

EU02 10/17/2006 Nov-06 Both X X X MACT compliance 21.96

BORA-1 DFF1 EU02 2/15/2007 Feb-07 Both X X X MACT compliance - failed 11.87

BORA-1 DFF1 EU02 3/28/2007 3/38/2007 Both X X X MACT compliance 11.42

BORA-11 AA-001 4/22/1999 Jun-99 Uncontrolled X X SO2 Permit Compliance 9.23

BORA-12 KLN 3/12/2002 Mar-02 Uncontrolled X X Permit Compliance unknown

BORA-13 EU04 12/13/2005 Jan-06 Uncontrolled X X X

Sulfuric Acid mist 

, SO2 Permit Compliance 19.87

BORA-13 EU04 2/7/2006 Feb-06 Uncontrolled X X X

Sulfuric Acid mist 

, SO2 Permit Compliance 23.56

BORA-13 CD1 7/25/2007 Jul-07 Both X X X Permit Compliance Lime feed rate 214 lb/hr 18.94

BORA-17 5BK 9/8/2005 Sep-05 Uncontrolled X X X

Sulfuric Acid mist 

, SO2 Permit Compliance 8.2

BORA-17 DIFF1 2/13/2007 Feb-07 Controlled X X X Permit Compliance 20.3

BORA-17 DIFF1 7/20/2007 Jul-07 Controlled X X X Permit Compliance unknown

BORA-19 CD01 EU02 5/25/2006 Jun-06 Both X X X Nox, SO2, CO Synethic Minor Location 17.64

BORA-19 CD01 EU02 8/8/2006 Aug-06 Controlled x X Synethic Minor Location 18.14

BORA-19 CD01 EU02 3/14/2007 Mar-07 Controlled X So2, CO Synethic Minor Location 18.14

BORA-3 CE41 EU41 11/2/2006 Nov-06 Controlled X X X Compliance MACT 10.01

BORA-3 DIFF EU05 11/1/2006 Nov-06 Both X X X Compliance MACT 19.86

BORA-3 CE41 EU41 10/16/2002 Nov-02 Controlled X X X Adjusting operating parameters 8.26

BORA-3 CE41 EU41 10/17/2002 Nov-02 Controlled X X X Adjusting operating parameters 8.26

BORA-3 CE41 EU41 10/14/2003 Nov-03 Controlled X X X Adjusting operating parameters 9.28

BORA-5 CD-1 003 &004 5/15/2007 May-07 Both X X X SO2 Compliance MACT 12.07

BORA-6 ES02 11/4/1998 11/4/1998 Uncontrolled X X State Compliance 5.9

BORA-7 DA-1 8/3/1999 Aug-99 Both X X SO2 Permit Compliance 19.66

BORA-7 DA-1 8/1/2001 Aug-01 Both X X x SO2 20.92

BORA-7 DA-1 3/13/2002 Mar-02 Controlled X X Initial Test 21

BORA-7 DA-1 5/25/2004 May-04 Controlled X PM10 Permit Compliance 20.8

BORA-20 D74 12/15/1999 Jan-00 Uncontrolled X X SO2, Nox, CO Internal Use 9.4

BORA-20 D76 12/2/1999 Jan-00 Uncontrolled X X SO2, Nox, CO Internal Use 7.34

POLLUTANTS TESTED (Please put X in box to indicate pollutant 

was tested)

090000648192f15d

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

Compilation from all Boral sites with 

Control Devices*

*BORA-1, BORA-3, BORA-5, BORA-7, BORA-13, BORA-17,BORA-18,BORA-19

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

Electricity cost, $/kwh $0.061

Reagent: Hydrated Lime

Reagent Cost, $/ton $110

Waste Reagent disposal cost, $/ton $105

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 

(Manhours) Frequency Staff Level

Develop a start-up, shutdown, and 

malfunction plan Develop plan and educate staff 80

1 Manager

Develop and implement an operating, 

maintenance, and monitoring plan Develop plan and educate staff 80

1 Manager

Bag replacement Replace single bag 16

As needed 

(e.g. when VE 

present) Maintenance

Bag replacement Replace all bags 120 Every 3 years Maintenance

Maintain free-flowing lime (Describe action in 

next box and then add estimated burden) Calibration and visual checks

4

Yearly 

calibration Maintenance

Daily Maintenance (list activity(ies) in next 

column) See example logs 1 to 1.5 hrs Daily Operator

Weekly Maintenance (list activity(ies) in next 

column) See example logs 1 to 2 hrs Weekly Maintenance

Monthly Maintenance (list activity(ies) in next 

column)

Greasing, Quarterly build-up issues can 

take considerable time to resolve 2 to 18 hrs Monthly Maintenance

Semi-Annual Maintenance (list activity(ies) in 

next column)

Requires system shutdown to inspect duct 

work 8 to 12 hrs Semi-annual Maintenance

Yearly Maintenance (list activity(ies) in next 

column)

Hours in addition to semi-annual & 

monthly checks 4 to 20 hrs Yearly Maintenance

Other Frequency Maintenance (specify 

frequency and list activity(ies) in next 

column) See example logs 3 hrs Quarterly Maintenance

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

Ensure that hopper is full. Arrange for and 

manage deliveries. 1 hr Daily Manager

Daily Maintenance (list activity(ies) in next 

column) Checks, empty pealing drum hoppers 4 hrs Daily Operator

Weekly Maintenance (list activity(ies) in next 

column) Miscellaneous checks & maintenance 1 hr Weekly Maintenance

Monthly Maintenance (list activity(ies) in next 

column) Miscellaneous checks & maintenance 4 hrs Monthly Maintenance

Semi-Annual Maintenance (list activity(ies) in 

next column)

Yearly Maintenance (list activity(ies) in next 

column)

Clean-out system, plenums, etc. (requires 

out-side contractors) 10 hrs Annually Manager

Other Frequency Maintenance (specify 

frequency and list activity(ies) in next 

column)

Lime delivery (2x/month) problems, 

patching pnuematic lines, replacing 

screens, etc. 20 hrs Quarterly Maintenance

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)

Composite Tests Costs for last 3 years Both 237,000

Examples:

Bessemer 6 (BIA-111)

Method 26A, Method 5, Method 6C, 

inhouse Method 9. Both 23000

Concurrent testing of 

2 Inlets + 1 Outlet. 

Inhouse Method 9 

($400)

Salisbury 6 (BIA- 103, 6BK)

Method 26A, Method 5, & inhouse 

Method 9 Both 6100

Inhouse Method 9 

($400). Pre-test flows 

($300 additional).

Augusta 4 (BIA-096, EU41)

Methods 5/26a for PM, HCl, HF; 3a for O2 

CO2; 6c for SO2; 7e for NOx;& 10 for CO; 

25a for VOC; 201a and 202 for PM10; & 9 

for in-house VE Controlled 9700

Inhouse Method 9 

($400)

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- Baghouse/DIFF/DLS

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

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

090000648192f15d

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

INFORMATION IS BEING SUPPLIED VIA HARD COPY UNDER CBI PRIVILEGE

090000648192f15d

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

Example: Boral has installed 5 retrofit DIFF Control devices with 

total costs ranging from $2.2 to 2.5M each. Detailed costing can 

be supplied, as necessary. 

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.

Yes. Clemson and Mission Clay test data (mass-balance before 

and after firing) for HF, HCl, & SOx for various sites.

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.

Can supply, as needed.

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.

No periodic kilns.

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

information regarding technological and/or economic 

limitations to testing those kilns?

No periodic kilns.

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

your facility, if available.

The process flow diagrams are basically unchanged from the 

1998 ICR submittals with the possible exception of APCD 

additions. Some generic examples of uncontrolled sites are 

provided for reference - see next tab.

090000648192f15d

FORM G - Additional Questions 11/17/2014




Feeders Crushing Mixing Feeder Extruding Coloring &

Texturing

Sand Slurry

EMISSION FLOW

MATERIAL FLOW

UNCONTROLLED STACK S-1

Rotary Dryer

RD1

Drying

(D1, D2, D3)

S-2, S-3, S-4

Firing

(TK1)

S-5

Packaging

and Storage

Setting

Water

Mixing

BORAL BRICKS, MARSHALL PLANT

PROCESS FLOW DIAGRAM

S-1

Raw Material

Storage

Stockpile

Additive

Feeder

Grinding

Crushing

Brick Batts

Brick to Yard




Blasting

P1-F-E-01

SCC 3-05-046-01

Dump Truck

Loading

P1-F-E-02

SCC Unassigned

Dump Truck

Unloading

P1-F-E-03

SCC Unassigned

Prim ary Crushing

P1-P-S-04

SCC 3-05-046-15

Front End Transfer

P1-F-E-08

3-05-046-03

G rinding and

Screening

SCC 3-05-046-19

Fine Clay Storage

P2-P-E-12

SCC 3-05-046-02

Form ing, Cutting,

and Stacking

Operations

1 1 1 1

1

1

1

1

2

Raw Material Transfer (Unpaved Roads)

P4-F-S-05

SCC 3-05-046-03

Conveyor to Grinding &

Screening

P1-F-S-09

SCC 3-05-046-03 Conveyor to Fine

Clay Storage

P2-F-E-11

SCC 3-05-046-03

Conveyor to

Forming Operations

P2-F-E-13

SCC 3-05-046-03

Conveyor to Crude Clay

P1-F-E-06

SCC 3-05-046-03

Sand Mixing

P3-P-E-14

SCC Unknown

Sand Coating

P3-P-E-15

SCC Unknown

Holding Room

P3-P-E-16

SCC Unassigned

Natural Gas Fired

Kiln No. 1

P3-P-S-03

SCC 3-05-003-11

Brick Dryers 3&4

P3-P-E-02(3,4)

SCC 3-05-003

Brick Dryers 1&2

P3-P-E-01(1,2)

SCC 3-05-003

Natural Gas Fired

Kiln No. 2

P3-P-S-04

SCC 3-05-003-11

1

1

2

2

3 4 2

3 4

Crude Clay

Storage

P1-F-E-07

SCC 3-05-003-03

Clay

Delivered

From Offsite

1

1 1

1

Storage and

Shipping

Boral Bricks, Bessem er Plant #6

Septem ber 2002

Legend

1

2

3

4

PM/PM 10 Em issions

O rganic Pollutant Em issions

Gaseous Emissions From Fuel Combustion

Hydrogen Fluoride Emissions

1

P1, Crude Clay Processing & Handling

P2, Fine Clay Processing & Handling

P3, Form ing & Drying Processes

Process Description

Process Flow Diagram

Initial Drying

P1-P-E-05

1

G rinding and

Screening Fabric

Filter

P2-P-S-10

SCC 3-05-046-19

Sand Storage

Silos

P3-P-E-14a

SCC Unknown

1

3

Feed Hoppers

(3)

Special Shapes

Forming, Cutting

and Stacking

Operation

1

3 belt feeders to

2 feed conveyors

Conveyor from Fine

Clay Storage

1

Special Shapes

Extrusion Line

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