### Ammm memi abima Amism .Naru" xmmm 11IIIIIIII1IIIIII

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# B R I C K C O M PA N Y 701 N. MAIN STREE LEXINGTON, NORTH CAROLINA 2729 INCORPORATED IN PHONE 336-248-85•

1909 f )_ TOLL FREE 800-672-611 

# II-D-®97 

# A.9

1 9 1 .30
NOTICE
Cunningham Brick Company, Inc. on January 1, 1998 acquired the physical assets of this brick plant. Records regarding operating data for the subject year are not available. Cunningham Brick Company, Inc. has begun construction data with its Environmental Engineering Firm toward the submittal of a Title V permit application.

## Enclosure 2 NOT SUBJECT TO T:i_ REO.I'RE1!ENiS OF II SSCTION 3577, PAPERSIORK RE7UCTIOr! AC' OE 19d0. 

## ~I ~ 

## INFORMATION REQUEST FOR BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURING OPERATIONS I. Instructions Please return the completed information request to:



# ~ KS ~ r•> - , , 

## F Bruce C. Jordan, Director Attn: Bill Neuffer Emission Standards Division (MD-13) U. S. Environmental Protection Agency Office of Air Quality Planning and Standards Research Triangle Park, North Carolina 27711 If you need clarification of any question or item, please contact Mr. Bill Neuffer of EPA at (919) 541-5435. 

## This information request should be completed for each facility that manufactures brick and structural clay products, including facilities that are not major sources. Information is requested for all processes at your plant that emit hazardous air pollutants (HAP's), including those processes that are not associated with brick and structural clay products manufacturing. Sections II through VII request information specific to brick and structural clay products manufacturing, and Section VIII requests information on emissions of HAP's from other processes located at the facility. Processes that may emit HAP's include those processes that use or handle any materials that contain a HAP compound, all processes with elevated temperatures, and all other processes iri which HAP compounds may be formed. The HAP list from Section 112(b) of the Clean Air Act is included as Attachment 1 to this information request. Attachment 2 provides background information on the requirements of the Clean Air Act and explains how the information requested in this questionnaire will be used by EPA. Attachment 3 is a list of abbreviations and acronyms used in this information request. Several tables are provided throughout the information request for your convenience in answering the questions. An example response is given (shaded first column or row) in each table. If additional space is needed to respond, please make copies of applicable pages. If necessary, please make copies of this information request for additional facilities. No additional emission testing or monitoring is required to respond to this request. II. General Facility Infotmation A. Name of company ~~~~ i.~HA~ ~ 

## 'e ~ 

## `.rr
~ 

## ° • ~ -~'`'~ • 

## Name of facility 61lePFt ' 9,."o (f : pe

, ~ 

### Ty


## Page 1 of 28 IL

## Facility address: No. _aad street _ 

# .Z /

9 .. 7 2 City 

# 6R6ve-4 State 

# N. G. Zip 

# dVLA _ Latitude and longitude coordinates of plant: .3.5 & 

# /D ' 38 " F/

10 ZS ~ 

## Standard Industrial Classification (,SIC) Code(s) of brick and structural clay products manufacturing operations 

# 3 ~ 

## .5 / Dun and Bradstreet No

. 

# N/A Total No. of employees for company 

# 41 ! for facility 

# 34 (If facility is a foreign subsidiary or if company has foreign subsidiaries, include number of employees not based in the U.S.). Please complete the following shift information for the facility: Shift No. of employees Hours per shift Days per year 

# 1 9 g 2 ~ ~GS 

# 3 B. Respondent name ' Wl C ~ 

## H' 4 RP VJ- CZ"'"'" 1AJy N•+•+- Respondent title Respondent address (if different from above) and telephone number: No. and street 

# 7O( xl. mAm ) -fr City 

# ~ jXN State) G• Zip o 2 — 1 2 9 2, 

## Telephone No. (__) .j~~ 

# y 7 2 '~l~ 

# / V/y1 •,EXi. , ~ 

# Z/ 7 Name and telephone number of technical contact person (if different from above) Name Telephone No. (__) III. Information on Operating Permits and Applicable Federal Emission Standards A. Please provide copies of relevant parts of all operating permits and permit applications for your facility. Relevant parts include the sections that providespecific information and data on: processes that emit HAP's; the use of HAPcontaining substances; emission levels for HAP and surrogate pollutants (i.e., VOC Page 2 of 28
12)

## for organic HAP's and PM for metal and other particulate HAP's); emission control device design and operation; monitoring and operation and maintenance (O&M) proce'dures for control devices; and generation and releases of other media such as wastewater and solid waste that are associated with the operation of air pollution controls for brick and structural clay products manufacturing processes. If the operating permit or application contains the same information requested in any part of this questionnaire, you may respond to the requested information by referencing the page or section of the permitlapplication to avoid duplication. If you reference your permit or application, you must supplement your response with all of the additional information requested in this questionnaire that is not included in the permit or permit application. If you prefer, you may submit the requested information from your permit/application on a 3-'/z inch diskette. B. If any source or emission unit at this facility is subject to a New Source Performance Standard or other Federal emission standard, please identify the source and applicable standard. Examples of applicable NSPS include 40 CFR 60, Subpart 000 - Standards of Performance for Nonmetallic Mineral Processing Plants, and 40 CFR 60, Subpart UUU - Standards of Performance for Calciners and Dryers in Mineral Industries.

IV. Brick and Structural Clay Products Production and Raw Material Consumption Information A. Please provide the 1996 production rates and the current production capacity for each type of brick and structural clay product manufactured (e.g., structural brick, clay sewer pipes, structural clay tile, etc.). Note that production data should be provided in units of tons per year (tons/yr). Product 1996 production (tons) Production capacity (tons/yr) 7XvGTv.C , 4 t- 

## /1 r C-k



## Page 3 of 28 

# a

## B. Please provide the type and amount of each raw material and body additive used in 1996 

# f nr manufacturing brick and structural clay products at your facility. Examples include clays, shale, and any additives that are mixed into the raw material prior to forming. Indicate additives by chemical compound, rather than by trade name. If the information requested is contained in your facility's operating permit, you may reference the applicable sections of the permit rather than providing the information below. Raw materiaUbody additive I Amount used in 1996 (tons/yr) dT



## C. If available, please provide a copy of the MSDS's for the raw materials and additives listed above. N144 D. If available, please provide chemical analyses, including fluorine, metals, and organic content, of the raw materials listed above. N 

# ~~

Page 4 of 28 

# 6

## E. Using Table 1, please provide information on the consumption and HAP composition of all glazes and colorants that contain HAP's or HAP precursors and that'your facility applies to brick and structural clay products. Indicate whether the coatings are glazes or colorants. Also indicate the type of product that the coatings are applied to and the total weight of coatings used in 1996. If the glazes or colorants are formulated at your facility indicate so and provide the production capacity. List each ingredient of the glaze or colorant. Beside each ingredient, indicate the total amount of the ingredient used in 1996. If the information requested in the table is contained in your facility's operating permit or permit application, you may reference the applicable sections of the permit (or application) rather than filling out the table. F. In the space below, please indicate any glazes or colorants used by your facility that do not contain HAP's and are substitutes for HAP-containing glazes or colorants used by your industry. Indicate which HAP-containing materials the non-HAP glazes or colorants replace. Describe any limitations on the use of those substitute glazes or colorants. 

# ZVaA/E

G. If your facility colors brick and structural clay products by flashing, please indicate the types of substances used to flash the products and the amounts of those substances used in 1996. Substance Amount used in 1996 Units (specify) 

# NeT - KAJaZ-s.

~



# /

H. If available, please provide a copy of the MSDS's for the glazes and colorants used by your facility. If your facility prepares its own glaze, please provide any available MSDS's for the glaze ingredients.
Page 5 of 28 

# I

## TABLE 1. CONSUMPTION AND HAP COMPOSITION OF GLAZES AND COLORANTS

Type (e.g., glaZecolorant) EXAMPLE•

~ 

# Glaze Co~o~ 

## e.a•vr Type of product glazed or Structural tile colored 

# ~ R6Gx 

## 1996 consumption (tons/yr) 1,140 : No T K•v106aW 

## Produced at facility? (yes/no)
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If additional space is required, please make copies of this page. If the information requested in the table is contained in your facility's operating permit or permit application, you may reference the applicable sections of the permit (or application) rather than filling out the table. Page 6 of 28

## V. Description of Brick and Structural Clay Product Manufacturing Processes A. Please provide a simple process flow diagram for each brick and structural clay product manufacturing process line. An example process flow diagram is provided in Figure 1. A diagram of the plant layout with all processes and emission points clearly labeled is also acceptable. Assign a unique identification number (ID No.) for each process that has associated emissions (e.g., TK-1 for tunnel kiln no. 1) and each emission point. Please identify all ernission points, including those that do not emit HAP's. For emission points that are vented to an air pollution control device (APCD), assign an ID No. to the APCD (e.g., BH-1 for baghouse no. 1). For emission points that are uncontrolled, assign an ID No. to the uncontrolled stack (e.g., S-1) or building roof vent (e.g., RV-1). Use these same ID Nos. throughout the rest of the information request for any responses that pertain to any process or emission point.

Page 7 of 28



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## Page 8 of 28

## B. Using Tables 2A and 2B, please provide current production rates, production capacities, and related information for each type of equipment used in brick and strucdial clay product manufacturing. In Table 2A, provide the requested information for only those sources that are known or expected to emit HAP's. In Table 213, provide the requested information for all thermal processing, such as drying and firing sources. For combustion sources that use different fuels, Table 2B should be completed for each type of fuel. For example, if a kiln typically is fired with gas, but periodically is fired with oil, one column in Table 2B should be completed for the kiln when fired with gas, and another column should be completed for the same kiln when fired with oil. Provide the data in the units listed for each row.

Page 9 of 28n

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## C. Using Table 3, please provide information on procedures used to monitor the process operating rate for each of the pieces of equipment and HAP emission sot.irces listed in Tables 2A and 2B. Use the same HAP emission source types and equipment ID numbers you listed in Tables 2A to 2B. Indicate whether you monitor process rate or not. Provide a summary of process rate monitoring procedures that describes how process rate is measured for the particular piece of equipment. Include where the rate is monitored (i.e., rate of material fed, rate of material discharged, or material production rate), the units used to measure process rate (e.g, lb/hr or pieces/hr), and how the process data is recorded, i.e., manually, automatically (e.glomputer - printout or stored to disk, or not at all). If you monitor process tate at both the feed and discharge ends of the equipment, indicate so. Indicate the type of monitor, equipment, or instrument used to measure process operating rate. Indicate the monitoring frequency or how often process rate measurements are made. If instruments are used to measure process throughput, indicate in the monitor accuracy column the accuracy of the instrument. The monitor accuracy could be listed in terms of a percentage of the throughput (t 1 percent), mass per unit time (±2 lb/hr), number of pieces per unit time (± 10 pieces/hr), or other appropriate units. Indicate the frequency that the monitor is calibrated. Provide data in the units listed for each row.

Page 12 of 28 

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## Page 13 of 28

## VI. Identification of Brick and Structural Clay Product Manufacturing Emission Points 

## A. Uses`the process flow diagrams developed for your facility and Table 4 to provide the following information for each HAP emission source at your facility. • Define HAP emission source type in terms of equipment, such as dryers, kilns, etc. As in the process flow diagram, you may group multiple pieces of similar equipment. • Use the same equipment ID numbers indicated on the process flow diagram(s). • If the emission source vents inside a building or to outside ambient air without first passing through a control device, place a check mark in the uncontrolled column. • If the emission source vents inside a building or to outside ambient air after passing through a fabric filter, dry injection fabric filter, or scrubber, place the APCD ID number(s) in the column corresponding to the APCD type. • If the emission source vents through a control device type not listed in Table 4, indicate the control device type in the other control column and place the APCD ID number in the appropriate cell. • In the emission test data colunm, place a"yes" or "no" in the appropriate cell to indicate whether the specific source has been tested for My pollutants, including any HAP's, VOC, PM, or opacity.

Page 14 of 28 

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## Page 15 of 28 

# \~

## B. Using Table 5, please provide information on stack parameters and emission estimates for each emission point at your facility that is known or expected to emit

- 

## HAP's. Provide information for all APCD's, including those that exhaust inside the building. Include data for each inlet and outlet, if available, as indicated in the table. If you have more than one inlet to an APCD, provide data for each of the inlets. Provide data in the units listed for each row. Provide emission estimates for any HAP's or HAP surrogates, such as PM for metal HAP's or VOC for organic HAP's. Emission estimates may consist of measurements reported in emission test reports or may be calculated using mass balances, emission factors, engineering judgement, or other estimation methods. Provide the emission estimates as emission factors in units of lb of pollutant emitted per ton of product (lb/ton). Provide complete copies of any emission test reports or other reports that document measurements of emissions. Test reports and other emission measurement documents should include the following information: process identification; location of sampling point; stack diameter, temperature, and flow rate; test method, including analytical procedures; number of test runs; emission concentration, emission rate, percent oxygen, and percent moisture for each test run; process operating rate; type of APCD; and APCD operating parameters. However, test reports with incomplete documentation may still be useful and should also be submitted. You do not need to fill out Table 5 for emission points that are covered by an emission test report that is included in your submittal. If emission test reports are not available, provide calculations that support your emission estimate, including the basis for all assumptions in the estimate. Note that emission estimates are needed for all HAP's that the facility emits or has the potential to emit. (Please refer to the HAP list in Attachment 1.) If the information requested in the table is contained in your facility's operating permit, you may reference the applicable sections of the permit rather than filling out the table.

Page 16 of 28 

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# v

## C. Using Tables 6A through 6D, please provide design and operating data for each APCD associated with all dryers, kilns, and any other brick and structural clay products mar ufac

~ 

## furing source that may emit HAP's. Use Tables 6A to 6C for specific types of APCD's. Use Table 6D for other types of APCD's. When using Table 6D, please specify the type of control device and 2 to 4 key design or operating parameters for the device. Provide data in the units listed for each row. If the information requested in Tables 6A through 6D is contained in your facility's operating permit, you may reference the applicable sections of the permit rather than filling out the tables.

Page 19 of 28 

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## D. Using Table 7, please provide the following information on current monitoring procedures for each of the control devices listed in Tables 6A to 61): parameters monitored (e.g., baghouse pressure drop), monitoring frequency, monitoring devices used (e.g., differential pressure transducer, thermocouple), and recordkeeping practices (e.g., manually recorded in log book, continuously recorded by electronic data acquisition system). Describe briefly other operation and maintenance (O&M) procedures for each control device. If the information requested in the table is contained in your facility's operating permit, you may reference the applicable sections of the permit rather than filling out the table. VII. Pollution Prevention Practices for Brick and Structural Clay Products Manufacturing A. Please describe all pollution prevention practices (i.e., process modifications, such as re-use of discarded or rejected materials, or any practice that prevents or reduces the amount of air emissions, or the generation and release of solid waste or wastewater associated with the operation of air pollution controls). If the information requested here is contained in your facility's operating permit, you may reference the applicable sections of the permit rather than providing the information below.

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## VIII. Information on Processes Other Than Brick and Structural Clay Products Manufacturing



# Processes A. Using Table 8, please identify all other processes or operations at this facility that are not addressed in Items II through VII above and that are potential sources of HAP emissions. Estimate total annual emissions of each HAP emitted by these colocated processes. If the information requested in the table is contained in your facility's operating permit, you may reference the applicable sections of the permit rather than fllling out the table.

Page 27 of 28



# ~~

## TABLE 8. ESTIMATED ANNUAL HAP EMISSIONS FROM OTHER SOURCES

Process/emission source/SIC Code(s) HAP's emitted Estimated a.nnual emissions, tons

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## If the information requested in the table is contained in your facility's operating permit, you may reference the applicable sections of the permit rather than filling out the table. Page 28 of 28 , O 

# ~

## Enclosure 2 NOT SUBJECT TO 7:!E REC;i:REa1ENTS OF I SiCTION 3507, PAPERLIORK REOUCTION ACT OF 1930. , 

### ~ 

## INFORIvIATION REQUEST FOR BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURIlVG OPERATIONS I. Instructions Please return the completed information request to: Bruce C. Jordan, Director Attn: Bill Neuffer Emission Standards Division (MD-13) U. S. Environmental Protection Agency Office of Air Quality Planning and Standards Research Triangle Park, North Carolina 27711 If you need clarification of any question or item, please contact Mr. Bill Neuffer of EPA at (919) 541-5435. 

## This information request should be completed for each facility that manufactures brick and structural clay products, including facilities that are not major sources. Information is requested for all processes at your plant that emit hazardous air pollutants (HAP's), including those processes that are not associated with brick and structural clay products manufacturing. Sections II through VII request information specific to brick and structural clay products manufacturing, and Section VIII requests information on emissions of HAP's from other processes located at the facility. Processes that may emit HAP's include those processes that use or handle any materials that contain a HAP compound, all processes with elevated temperatures, and all other processes in which HAP compounds may be formed. The HAP list from Section 112(b) of the Clean Air Act is included as Attachment 1 to this information request. Attachment 2 provides background information on the requirements of the Clean Air Act and explains how the information requested in this questionnaire will be used by EPA. Attachment 3 is a list of abbreviations and acronyms used in this information request. Several tables are provided throughout the information request for your convenience in a.nswering the questions. An example response is given (shaded first column or row) in each table. If additional space is needed to respond, please make copies of applicable pages. If necessary, please make copies of this information request for additional facilities. No additional emission testing or monitoring is required to respond to this request. II. General Facility Information A. Name of company ( ~ 

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## Facility address: No,,ud street 

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## Standard Industrial Classification (SIC) Code(s) of brick and structural clay products manufacturing operations Dun and Bradstreet No. Total No. of employees for company l

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## 8 

## for facility 

# g4 (If facility is a foreign subsidiary or if company has foreign subsidiaries, include number of employees not based in the U.S.). Please complete the following shift information for the facility: Shift No. of employees Hours per shift Days per year 1 2 

# F - 3 B. Respondent name - WIc, 4ARa W. C ~N~ 

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## Name and telephone number of technical contact person (if different from above) 

# Name Telephone No. (_) III. Information on Operating Permits and Applicable Federal Emission Standards A. Please provide copies of relevant parts of all operating permits and permit applications for your facility. Relevant parts include the sections that providespecific information and data on: processes that emit HAP's; the use of HAPcontaining substances; emission levels for HAP and surrogate pollutants (i.e., VOC Page 2 of 28 h ~

## for organic HAP's and PM for metal and other particulate HAP's); emission control device design and operation; monitoring and operation and maintenance (O&M) proce7ures for control devices; and generation and releases of other media such as wastewater and solid waste that are associated with the operation of air pollution controls for brick and structural clay products manufacturing processes. If the operating permit or application contains the same information requested in any part of this questionnaire, you may respond to the requested information by referencing the page or section of the perniit/application to avoid duplication. If you reference your permit or application, you must supplement your response with all of the additional information requested in this questionnaire that is not included in the permit or permit application. If you prefer, you may submit the requested information from your permit/application on a 3- 1 /z inch diskette. B. If any source or emission unit at this facility is subject to a New Source Performance Standard or other Federal emission standard, please identify the source and applicable standard. Examples of applicable NSPS include 40 CFR 60, Subpart 000 - Standards of Performance for Nonmetallic Mineral Processing Plants, and 40 CFR 60, Subpart UUU - Standards of Performance for Calciners and Dryers in Mineral Industries. P~, y ppjt 

## ~~ C IA,n4l4c TOi 

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## IV. Brick and Structural Clay Products Production and Raw Material Consumption Information A. Please provide the 1996 production rates and the current production capacity for each type of brick and structural clay product manufactured (e.g., structural brick, clay sewer pipes, structural clay tile, etc.). Note that production data should be provided in units of tons per year (tons/yr). Product 1996 production (tons) Production capacity (tons/yr) 2UGTWXAL 

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## Page 3 of 28 ti h.

## NORTH CAROLINA ENVIRONMENTAL MANAGEIVLENT COMMISSION

DEPARTMENT OF ENVIRONMENT, HEALTH AND NATURAL RESOURCES

~ 

## DIVISION OF AIR QUALITY

AIR PERMIT NO. 3241R15 Issue Date: October 3, 1997 Effective Date: October 3, 1997 Expiration Date: February 28, 2001 Replaces Permit: 3241R14 To construct and operate air emission source(s) and/or air cleaning device(s), and for the discharge of the associated air contaminants into the atmosphere. In accordance with the provisions of Article 21B of Chapter 143, General Statutes of North Carolina (NCGS) as amended, and other applicable Laws, Rules and Regulations, Cunnin l gham Brick Company, Inc. 1437 Cunningham Brick Yard Road Thomasville, Davidson County, North Carolina Site Number: 04/029/00222 (the Permittee) is hereby authorized to construct and operate air emissions sources and/or air cleaning devices and appurtenances consisting of 1. one coal/natural gas/No. 2 fuel oil-fired tunnel type brick kiln (23 million Btu per hour maximum permitted heat input), 2. one primary crusher (100 tons per hour maximum permitted capacity, ID No. 1GR), NSPS 3. one Claypactor hammermill (100 tons per liour maximuin capacity, ID No. 3GR), 4. six screens, each with dimensions of four foot by eight foot (ID No. 2GR), 5. one raw materials mixing and extruding process utilizing soil recovery-regeneration of petroleum contaminated soils through a pre-kiln dryer (ID No. D-1) utilizing waste heat from the kiln to pre-dry clay bricks prior to firing in the kiln, 6. one simple cyclone (36 inches in diameter) followed by one bagfilter (512 square feet of filter area) installed in series on a pulverized coal handling system (a hammermill followed by a pneumatic conveyor to the simple cyclone), 7. one simple cyclone (22 inches in diameter) and one bagfilter (25 square feet of filter area) installed on a drag box (ID No. 43M), 8. one portable brick nugget manufacturing facility (57 tons per hour maximum permitted cruslling capacity) consisting of: 

# '7A

## Permit No. 3 241 R 15

Page 2 a. one Kemco crusher with water spray bars (57 tons per hour maximum permitted

crushing capacity, ID No. SD-70), b. two Kemco crushing conveyors, 30 inches in belt widths each, C. one Nordberg four foot by sixteen foot double deck screen, d. one Titan five foot by ten foot triple deck screen,
e. one Titan belt feeder, 48 inches in width, f. one Titan conveyor, 47 1 /2 inches in width, g. four conveyors, 24 inches in belt widths each (ID Nos. 1M60, 2M60, 3M60 and ES8), h. one conveyor, 30 inches in belt width (ID No. 1 M70), one conveyor, 14 inches in belt width (ID No. ES 9), and 9. one natural gas-fired, rotary drum sand dryer (2.8 million Btu per hour maximum heat input, (ID No. SD-1), in accordance with the completed application (APP2900222.97A) received August 4, 1997, including any plans, specifications, previous applications, and other supporting data, all of which are filed with the Department of Environment, Health, and Natural Resources, Division of Air Quality (DAQ) and are incorporated as part of this Permit. This Permit is subject to the followin ~ 

## specified conditions and limitations including any TESTING. REPORTING, OR MONITORING REOUIREMENTS:

A. SPECIFIC CONDITIONS AND LIMITATIONS 1. Any air emission sources or control devices authorized to construct and operate above must be operated and maintained in accordance with the provisions contained herein. The Permittee shall comply with applicable Environmental Management Commission Regulations, includin; Title 15A North Carolina Administrative Code (NCAC), Subchapter 2D .0510, .0515, .0516, .0518, .0521, .0522, .0524 (40CFR60, Subpart 000), .0535, and Subchapter 2Q .0507. 2. PARTICULATE CONTROL REOUIREMENT - As required by 15A NCAC 2D .0515 "Particulates from Miscellaneous Industrial Processes," particulate matter emissions from the tunnel type brick kiln, the materials mixin ~ 

## and extruding process, and the sand dryer shall not exceed allowable emission rates. The allowable emission rates are, as defined in 2D .0515, a function of the process weight rate and shall be deteiniined by the following equations(s), where P is the process throughput rate in tons per hour (tons/hr) and E is the allowable emission rate in pounds per hour (lbs/hr).

Az r,

## Permit No. 3241 R 15

Page 3 E= 4.10 *( P)" 7 for P_< 30 tons/hr, or

E= 55:0"* ( P)" 11 -40 for P > 3 0 tons/hr. 3. REPORTING REOUIREMENT - Subsequent to the submittal of the Title V permit application, pursuant to 2Q. 0507, the Permittee, upon becoming aware that any relevant facts were omitted or incorrect information was submitted in the Title V application, shall promptly submit such supplementary facts or corrected information to: Division of Air Quality, Post Office Box 29580, Raleigh, North Carolina 27626-0580. 4. The Permittee sllall take all reasonable precautions witli any operation, process, llandling, transportation, or storage facilities to prevent fugitive particulate, visible, and/or odorous emissions from becoming airborne. 5. As required by 15A NCAC 2D .0516 "Sulfur Dioxide Emissions from Combustion Sources," sulfur dioxide emissions from the fuel burning equipment sllall not exceed 2.3 pounds per million Btu heat input. 6. The regenerated soil processed in the equipment described in Item 5 shall only be tlle soil type described in the air permit application dated April 28, 1989. 

# For each shipment of regenerated soil, the following is required: a. Composite samples of regenerated soil shall be tested and verified for total petroleum hydrocarbons in accordance with EPA Test Methods 3550 and/or 5030. A representative sample shall be analyzed for volatile organic compound (VOCs), semi-volatile organic compounds, and polychlorinated biphenyl (PCB) by EPA Test Method 8240 and 8270. b. The manifest shall include weight of soil received and soil contamination documentation. The Permittee sllall retain manifests on site for a minimum of five (5) years from the manifest receipt date. 7. As requested by the Permittee, total annual volatile organic compounds emissions from processing contaminated soils shall not exceed ten tons. The Permittee shall keep annual records to verify this limitation. These records shall be retained on site for a minimum of five years. 8. As required by 15A NCAC 2D .0521, "Control of Visible Emissions," visible emissions from the kiln and brick nugget manufacturing facility, established after July 1, 1971, shall not be more than 20 percent opacity when averaged over a six-minute period, except that six-minute periods averaging not more than 87 percent opacity may occur not more than once in any hour nor more than four (4) times in any 24-hour period. However, sources which must comply with 15A NCAC 2D .0524 "New Source Performance Standards" or .1110 "National Emission Standards for Hazardous Air Pollutants" must comply with applicable visible emissions requirements contained therein. 9. As required by 15A NCAC 2D .0521, "Control of Visible Emissions," visible emissions from the crusher (ID No. 1GR), screens (ID No. 2GR), pulverized coal handling system, drag box



# ~~

## Permit No. 3241R15

Page 4 (ID No. 43M), rotary drum sand dryer and the raw materials mixing and extruding process ,existing as of July 1, 1971, shall not be more than 40 percent opacity when averaged over a sixminute period; 'txcept that six-minute periods averaging not more than 90 percent opacity may occur not more than once in any liour nor more than four (4) times in any 24-hour period. However, sources which must comply with 15A NCAC 2D .0524 "New Source Performance Standards" or .1110 "National Emission Standards for Hazardous Air Pollutants" must comply with applicable visible emissions requirements contained tlherein. 10. As required by 15A NCAC 2D .0522, "Control and Prohibition of Odorous Emissions," the permittee shall not cause, allow, or permit any source to be operated without employing suitable measures for the control of nuisance odors. 11. 15A NCAC 2D .0524 "NEW SOURCE PERFORMANCE STANDARDS" - For the Claypactor hammermill (ID No. 3GR), the Permittee shall comply with all applicable provisions, including the notification, testing, reporting, record keeping, and monitoring requirements contained in Environmental Management Commission Standard 15A NCAC 2D .0524, "New Source Performance Standards" (NSPS) as promulgated in 40 CFR 60, Subpart 000, including Subpart A "General Provisions." 12. 

# FABRIC FILTER REOUIREMENTS - Particulate emissions from the pulverized coal handling system shall be controlled by a bailter with 512 square feet of filter area and the drag box (ID No. 43M) shall be controlled by a bagfilter with 25 square feet of filter area. (a) Inspection and Maintenance Requirements To comply with the provisions of this Permit and ensure that maximum control efficienc_y is maintained, the Permittee shall perform periodic inspections and maintenance as recommended by the manufacturer. The record keeping schedule is given below. An annual internal inspection shall be conducted on the bagfilters by the Permittee to ensure structural integrity such that optimum control efficiency is achieved. The results of this inspection, and any maintenance performed on the bagfilreirs, shall be recorded in a log book which is described below and which will be kept on site and made available to the DAQ upon request. (b) Record Keeping Requirements A fabric filter log book shall be kept on site and made available to DAQ persomiel upon request. Any variance from manufacturers recommendations or from those given in the permit (when different) sliall be investigated with corrections made and date of actions recorded in the log book. The log book shall also contain the records of any maintenance performed on the bagfilter system and the results of inspections including a broken bag chart (where applicable). 13. 

# CYCLONE REQUIREMENTS - Particulate matter emissions from the pulverized coal handli»g system shall be controlled by a 36 inch diameter simple cyclone and the drag box (ID No. 43M) shall be controlled by a simple cyclone 22 inches in diameter. 

# 3~

## Permit No. 3241 R 15

Page 5 (a) Inspection and Maintenance Requirements To comply'with the provisions of this Permit and ensure that optimum control efficiency is maintained, the Permittee sliall establish an inspection and maintenance schedule and/or checklist based on manufacturer's recommendations and record the results. The inspection and maintenance program shall, as a minimum, include an annual internal inspection to ensure the structural integrity. The results of this inspection and any maintenance performed on the cyclone, sliall be recorded in a log book which is described below. (b) Record Keeping Requirements A cyclone log book which shall be kept on site and made available to DAQ personnel upon request. Any variance from the cyclone manufacturer's recommendations shall be investi g ated with corrections made and date of actions recorded in the cyclone log book. 14. NOTIFICATION REOUIREMENT - As required by 15A NCAC 2D .0535, or for sources applicable to 15A NCAC 2D .0524 or .1110, when particulate, visible, and/or odorous emissions exceed Environmental Manaszement Regulations for more than four (4) hours, the Regional Supervisor, Division of Air Quality, shall be notified as promptly as possible, but in no case later than twenty-four (24) hours or on the next working day of becoming aware of the occurrence. Such notice shall specify the facility name and location, the nature and cause of the excess emission, the time when first observed, the expected duration, and the estimated rate of emissions. This reporting requirement does not allow the operation of the facility in excess of Environmental Management Commission Regulations.

B. GENERAL CONDITIONS AND LIIVIITATIONS REPORTS, TEST DATA, MONITORING DATA, NOTIFICATIONS. AND REOUESTS FOR RENEWAL shall be submitted to the: Regional Supervisor North Carolina Division of Air Quality 585 Waughtown Street Winston-Salem, NC 27107 2. PERMIT RENEWAL REOUIREMENT - The Permittee, at least ninety (90) days prior to the expiration date of this Permit, shall request permit renewal by letter in accordance with 15A NCAC 2Q.03 04 (d) and (f). Pursuant to 15A NCAC 2Q .0203 (i), no permit application fee is required for renewal of an existing air permit. The renewal request should be submitted to the Regional Supervisor, Division of Air Quality. ANNUAL FEE PAYMENT - Pursuant to 15A NCAC 2Q .0203 (a), the Permittee shall pay the Annual Permit Fee within thirty (30) days of being billed by the Division. Failure to pay the fee in a timely manner will cause the Division to initiate action to revoke the permit. 

# --),I

## B. Please provide the type and amount of each raw material and body additive used in 1996 for manufacturing brick and structural clay products at your facility. Examples include clays, shale, and any additives that are mixed into the raw material prior to forming. Indicate additives by chemical compound, rather than by trade name. If the information requested is contained in your facility's operating permit, you may reference the applicable sections of the permit rather than providing the information below. Raw materiaUbody additive Amount used in 1996 (tons/yr) 5 ace 

# Sa 7s o Ben gip-. C LA /9 t.f0 r C- , 

# P d-YR le ✓ ro. 

# C

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### L 

## S DDO



## C. If available, please provide a copy of the MSDS's for the raw materials and additives listed above. 11 

# ~ 6 D. If available, please provide chemical analyses, including fluorine, metals, and organic content, of the raw materials listed above.



# /V/AP

Page 4 of 28 

# ,~ 

# C

## E. Using Table 1, please provide information on the consumption and HAP composition of all glazes and colorants that contain HAP's or HAP precursors and thaCpbur facility applies to brick and structural clay products. Indicate whether the coatings are glazes or colorants. Also indicate the type of product that the coatings are applied to and the total weight of coatings used in 1996. If the glazes or colorants are formulated at your facility indicate so and provide the production capacity. List each ingredient of the glaze or colorant. Beside each ingredient, indicate the total amount of the ingredient used in 1996. If the information requested in the table is contained in your facility's operating permit or permit application, you may reference the applicable sections of the permit (or application) rather than filling out the table. F. In the space below, please indicate any glazes or colorants used by your facility that do not contain HAP's and are substitutes for HAP-containing glazes or colorants used by your industry. Indicate which HAP-containing materials the non-HAP glazes or colorants replace. Describe any limitations on the use of those substitute glazes or colorants. 

# NoN ~



## G. If your facility colors brick and structural clay products by flashing, please indicate the types of substances used to flash the products and the amounts of those substances used in 1996. Substance Amount used in 1996 Units lspecify) NA7yRA 1 - G AI it/oT K. ✓ *w,y



## H. If available, please provide a copy of the MSDS's for the glazes and colorants used by your facility. If your facility prepares its own glaze, please provide any available MSDS's for the glaze ingredients.
Page 5 of 28 

# t-I c

# TABLE 1. CONSUMPTION AND HAP COMPOSTITON OF GLAZES AND CO 

# i.nu ANTR

Type (e.g., glaze : colorant) EXAMPLE: Glaze Type of product glazed or StructuraI tile ' 8,Q t C~ K colored 1996 consumption (tons/yr) ._:..,. 

# :.<.;.. . 1,140- '

. •. .,..>..-

~ 

### <,...: _. A.._ :. .. 

# Z y Produced at facility? (yes/no) ....., , ,. 

## S ye Production capacity (tons/yr) 

# ,+ s`4 'r'

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# Total usage (weight) of each Tofsl I996= ~ 

# = Total 1996 ingredient (that is a HAP, ~ ' ~ ~ 

# ientr:`- " • -

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# :.us$ge; : ;fons ~ 

# Ingredient usage, tons contains a HAP

, 

# or is a HAP precursor) in 1996 :
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. . 

## If additional space is required, please make copies of this page. If the information requested in the table is contained in your facility's operating permit or permit application, you may reference the applicable sections of the permit (or application) rather than filling out the table. Page 6 of 28

# Material Safety Data Sheet ,n 'man an s g e e Kn KERR-MCGEE"AHEMICAL CORPORAT/ON 

# dioxide

KERR-McOEE CENTER

## ■ OKLAHOMA CITY OKLAHOMA 73125 

### For more detailed information on the hazards of this product, contact Regulations Compliance Department or Medical Services Department at the address above. Technical Information Builetin Is aiso available. For emergency information, teiephone (405) 270-1313 any time. 

### PRODUCT IDENTIFICATION Brand Name
. . . . . . . . . . . . . . . KM manganese dioxide Chemical Name ............Manganese dioxide Common Name
. . . . . . . . . . . . Manganese dioxide Formula . . . . . . . . . . . . . . . . . . . Mn0 2 DOT Proper Shipping Name . . . . . ._... . . . Not applicable 

## DOT Hazard Class . . . . . . . . . . : . . . . . . . . . . . Not applicable DOT I.D. Number . . . . . . ., . . . Not applicabie 

## Reportable Quantity (RQ) . . . Not applicable CAS Number .. ......... ...1313-13-9 PHYSICAL AND CHEMICAL PROPERTIES State
. . . . . . . . . . . . . . . . . . . . . . . . . . . . Powden3d solid Melting Point C . . . . . . . . . . . . . . . . . .535 Boiling Point C . . . . . . . . . . . . . . . . . . . Decomposes 

### Color 

## ............................Biack Odor 

## ............................1lone Bulk Density, Ib/cu. ft ... . ... . . .. . .86 Weight Per Gallon
. . . . . . . . . . . . . . . . Not applicable Specific Gravity @ 20C . . ... ..... .5 Water Solubility
. . . . . . .. . . . . . . . . . . Insoluble Flash Point And Method
. . . . . . . . . . Not appiicable pH
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not appiicable HAZARDOUS INGREDIENTS Chemical Name Common Name CAS Number 

## Hazard Manganese dioxide Manganese dioxide 1313-13-9 Dust causes irritation of the eyes, nose, throat, and lungs. Repeated inhalation of dust or fumes may cause delayed injury to the central 

### nervous system. NOTICE:

~ 

### Under Section 313 of Title ill of the Superfund Amendments and Reauthorization Act (SARA) of 1986 

## and 40 CFR Part 372 i this is official notification that Manganese diox1de.(Mn02), 92%, CAS #1313-13-9 contains manganese, CAS #7439-96-5, which is Iisted as a toxic substance. -----•-••---••---•---•-• .......................................................................•--•----....................................................---.....---...........----............---••-•---......-----. PHYSICAL HAZARD INFORMATION Explosive: No Upper Explosive Limit: Not applicabie Lower Explosive Limit: Not applicable Pyrophoric: No 

## Flammable: No Flammability Class: Not applicable Combustibie: No Organic Peroxide: No Oxidizer: Yes Compressed Gas: No Reactivity: Stable at ordinary temperatures and pressures. 

## Incompatibilities: Organic materiais, combustibie materials, chlorates, aluminum powder, sulfur or other oxidlzable

materials. Hazardous None. When subjected to intense heat, temperature above 5350 (995 F), it will release oxygen Decompositlon: which would increase the intensity of a fire. 

## Conditions Incompatible materials and intense heat. To Avoid:

............... ......................................................................................................................................................................................................... 1 of 4 B-5019 

# ~ ?..

## HEALTH INFORMATION

Precautionary Information: CAUTIONI This product is abrasive to the eyes and skin. Dust from this product causes irritation of the eyes, nose, throat, and lungs. Repeated or prolonged inhalation of the dust or fumes may cause delayed injury to the central nervous system and kidneys.
Symptoms Of Exposure: Eye or skin irritation, fever, chills, nausea and vomiting, muscular aches and weakness, coughing, sneezing, bronchitis, Irregular walk and emotional disturbance.

Restrictive Medical . Eye, skin, respiratory, kidney or liver diseases or disorders would be aggravated by Conditions: repeated or prolonged exposure to the dust or fume from this chemical. Persons with a history of aicoholism, psychiatric, or neurologic disease would be at increased risk from exposure to manganese.

PRIMARY ROUTE(S) OF ENTRY Inhalation (breathing), Ingestion (swallowing), and eyes.

TOXICITY INFORMATION Manganese: 2.3 mg/m 3 inhaiation - human TCLo; 400 mg/kg intramuscular - rat TDLo; 45 mg/kg intravenous - rabbit LDLo; Prolonged administration of manganese in the drinking water of rats resulted in fetotoxicity and mutagenic effects. The threshold dose was 0.005 mg/kg. Long term exposure to high concentrations of manganese dust may lead to manganism, a disease of the central nervous system.

EXPOSURE LIMITS OSHA: Ceiling value 5 mg/m 3as manganese ACGIH: TLV - CEILING VALUE — 5 mg/m 3 as manganese. Other. Not applicable.

2 of 

## a 9-SOta 

# q3

### ------••--------••---•• ......................•--.............--••---.................................---..................--•-•----......---.....................................---..............................------



## Reported As A Potential Carcinogen ® Not Applicable • ❑ National Toxicology Program Or Carcinogen ❑ OSHA ❑ International Agency For Research On Cancer --•• .............................-....:: .:- :.....-•---...........---............................................---•-•---.....-----..........................................................................--------.. PRECAUTIONS FOR SAFE HANDLING AND USE Avoid breathing dust. Avoid contact with eyes, skin and clothing. Keep container closed. 

## Use with adequate ventilation. Wear a respirator. Wash thoroughly after handling.



## ~ ...........................•---............:.........._.......................-•--•----.....-•----...................-------•----......................--•----•--------..........-•---......---.._....----•--•---.... 

## SPILL AND LEAK PROCEDURES 

## Soil Release: Shovel up or vacuum up using a vacuum cleaner with an efficient filter.

Dispose of waste at an industrial waste site in accordance with any appiicable federai, state, or local regulations. 

## Water Spill: Dredge up and dispose of waste at an industrial waste site. Air Spill: When material has settled, handle as for Soil Release or Water Spill. Occupational Spill: Handle as outlined above for Soil Release or Water Spiil. Do not flush into drains, sewers or other water runoff. RCRA Waste Not applicable. Number.


## ENGINEERING CONTROLS AND PERSONAL PROTECTJVE EGIUIPMENT 

## Ventilation: Use local exhaust ventilation techniques to meet ceiling exposure limit. Respirator. For exposure exceeding ceiling limit and up to 50 mg/m 3 use NIOSH/MSHA approved dust & mist respirator except single use or quarter mask type. 

## Eye Protection: Face shield, safety glasses or vented safety goggles. Ensure that an eyewash fountain is In the

immediate work area. Gioves: Wear gloves that will not allow the product to penetrate. Clothing: Wear easily washable clothing. Change daily. Wash clothing before reuse.

3of4 B-5019 

# 0 Li

### ............................................................. EMERGENCY PROCEDURES 

## Fire: Material is not fiammabie, but may increase the intensity of a fire involving other materials. Wear

positive pressure seif-contained breathing apparatus with full face mask and full protective clothing. Evacuate all unnecessary people upwind from the fire and smoke. Fight fire using medla suitable for the materlals that are burning.



## Spill or Leak: Shovel or sweep up and place into ciean closed, dry container for later disposal. ~

FIRST AID PROCEDURES 

## Ingestion: If swallowed, induce vomiting immediately by giving two glasses of water and sticking finger down

throat. Never give anything by mouth to an unconscious person. Call a physician.

i 

## Inhalation: If inhaled, remove to fresh air. If not breathing, give artificial respiration, preferably mouth-to-mouth. If

breathing is difflcult, give oxygen. Cali a physician. Skin Contact: Flush skin with water and then wash thoroughly with soap or miid detergent and water.
Eye Contact: Flush eyes with plenty of water for at least 15 minutes. Call a physician.

Note To Chemical of exposure is manganese dioxide. Chronic exposure to manganese dust can lead Physician: to manganism, a disease of the central nervous system.

.......---•-•-• ........................•------.............................--•-••---...........-•--•--.................---..................................................-•--•--..................................... DATE OF ISSUE: January, 1990 DATE REVISED: January, 1990 REPLACES: February, 1989

4 of 4 B-5019

## V. Description of Brick and Structural Clay Product Manufacturing Processes A. Please
- provide a simple process flow diagram for each brick and structural clay product manufacturing process line. An example process flow diagram is provided in Figure 1. A diagram of the plant layout with all processes and emission points clearly labeled is also acceptable. Assign a unique identification number (ID No.) for each process that has associated emissions (e.g., TK-1 for tunnel kiln no. 1) and each emission point. Please identify all emission points, including those that do not emit HAP's. For emission points that are vented to an air pollution control device (APCD), assign an ID No. to the APCD (e.g., BH-1 for baghouse no. 1). For emission points that are uncontrolled, assign an ID No. to the uncontrolled stack (e:g., S-1) or building roof vent (e.g., RV-1). Use these same ID Nos. throughout the rest of the information request for any responses that pertain to any process or emission point.

Page 7 of 28 

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# B. Using Tables 2A 

# and 2B, please provide current production rates, production capacities, and related information for each type of equipment used in brick and structuial clay product manufacturing. In Table 2A, provide the requested information for only those sources that are known or expected to emit HAP's. In Table 2B, provide the requested information for all thermal processing, such as drying and firing sources. For combustion sources that use different fuels, Table 2B should be completed for each type of fuel. For example, if a kiln typically is fired with gas, but periodically is fired with oil, one column in Table 2B should be completed for the kiln when fired with gas, and another column should be completed for the same kiln when fired with oil. Provide the data in the units listed for each row.

Page 9 of 28~



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## Form B: General Information Facility ID # 2900222

North Carolina Department of Environment, Health, and Natural Resources Division of Air Quality Annual Pollutant Emissions Inventory

1996 

## Corporate Address (if different from facility address): w c- r-I 

## Contact: Mr. Richard W. Cunningham Telephone Number: 910-472-6181 U) 701 North Main Street Street Number and Name or P.O. Box Lexington North Carolina 27292 City State Zip Code 2. Billing Address (if different from facility address): Contact: Mr. Richard W. Cunningham Telephone Number 910-472-6181 

## 701 North Main Street Street Number and Name or P.O. Box Lexin g aton North Carolina 27292 City State Zip Code

., . • 

## 3. Geographic Coordinates:

Latitude 35 ° 47 ' 45 " Longitude 80 ° 8' I 2" 4. Tallest building dimensions (Feet): Length: 525 Width: 150 Height: 34 5. Distance from centroid of facility to closest property line (Feet): 850 feet GZA GeoEnvironmental, Inc. 6. Emissions Inventory Preparer: (William G. Colby, P.E.) Telephone #: 603-623-3600 Information on Form B cannot be held confidential.

\\gra\gca\joba\ —)1357\forau\cbcformb.doc 

# ~ A------ ---- ~ ------ ------ - - - --- ~-- ~ r~


## Form D: Process Information (1 of 2) Facility ID # 2900222



## North Carolina
- Departznent of Environment, Health, and Natural Resources Division of Air Quality Annual Pollutant Emissions Inventory



# 1996 

# D—( 1. Source ID No(s). Tunnel Kiln Dryer 2. Permit Item No(s). 1 3. Process Description: Pre-drying of clay brick prior to entering firing section of the kiln.
4. Operational Schedule: Hours per Days Weeks Hours Day 24 per 7 per year: 49 per year: 8232 Week: D

~ ~ 

## m
~



## 5. Start Hour of Process: Continuous 6. Percenta e annual throu h ut: Dec-Feb 19 Mar- 27 June-Aug 27 Sept-Nov 27 May 7. Maximum Process 8. Annual Process Rate per Hour: (ex: 22,000 lbs clay/hour Throughput: gal/hr, mmcf/hr) (ex: lb/yr, gal/yr)
- include units 9. Capture Efficiency (% of Process Emissions Vented Through Control Device 10. Control Device Descriptions Primary 77,000 tons/yr (actual) include units 

# none 

# NA Secondary 

# NA 11. Combined Control Device Efficiency (%): 

# NA 12. AIVNUAL FUEL USAGE (Coal, oil, wood, natural gas, etc.)-Use additional sheets if necessary. Type of Fuel Used Amount (gal, tons, mmcf/year) % Sulfur %Ash None 

# E I
6z

# D

~ 

## r 

## m
~ 

## Form D: Process Information (2 of 2) Facility ID# 

## 2900222 Source ID# 

## ESKD-1 Actual Emissions ger Pollutant,.Listed for Source Described Above: Attach calculations and documentation of emission factors or other estimation methods used. "Per Ton" Pollutant: TSP PM-10 SO, NO x VOC CO Net Control Efficienc (%): N/A N/A N/A N/A N/A N/A Actual Emissions: Tons/ r — — — -- .227 °

; ***All Other HAPs/TAPs as listed in Appendix C and Appendiz D(use additional sheets as necessary)***

Pollutant CAS Number Actual (lb./Year) Comments Benzene 71-43-2 .24 

# ~ Chlorine 7782-50-5 Ethyl Benzene 100-41-4 14.91 i Fluorine 778241-4 

# I Hydrazine 302-01-2 

# ~ Hydrogen Chloride 7647-01-0 I Hydrogen Fluoride 7664-39-3 

# ~ Hydrogen Sulfide 7783-064 Lead compounds LEADCPDS Methyl Chloroform 71-55-6 Methylene Chloride 75-09-2 .06 Naphthalene 91-20-3 14.05 Ozone 10028-15-6 Perchloroethylene 127-184 0.68 

## Phenol 108-95-2 Phosphine 7803-51-2 Toluene 108-88-3 18.29 Xylenes (total) 1330-20-7 338.79 Information requested on Form D cannot be held confidential.

Bolded Entries are those pollutants specifically listed by NCDAQ. \\gza\gu\;ob5\21857\rort »>\cbekind 2 .da 

# 4s

## s sm
~ 

# r , r^ 07 

## Form D: Process Information (1 of 3) Facility ID# 2900222 ..~



## North Carolina De(SaTtment of Environment, Health, and Natural Resources Division of Air Quality Annual Pollutant Emissions Inventory



## 1996 

# i K-1 l. Source ID No(s). Tunnel Kiln (E-8*l•) 2. Permit Item No(s). 1 3. Process Description: Dual fuel fired tunnel kiln (coal and natural gas) for firing clay bricks. 4. Operational Schedule: Hours per 

# ~ Days per Weeks per 49 Hours per Day 24 

## Week: 7 

## year: ye: az 8232 5. Start Hour of Process: C ontinuous 6. Percenta e annual throughput: Dec-Feb 19 Mar-May 27 June-Aug 27 Sept-Nov 27 7. Maximum Process 8. Annual Process Rate per Hour: (ex: 22,000 lbs clay/hour Throughput: 77,000 tons/yr gal/hr, mmcf/hr) (ex: lb/yr, (Tal/yr) (actual) include units include units 9. Capture Efficiency (% of Process Emissions Vented Through Control Device: 

# none 10. Control Device Descriptions Primary 

# NA Secondary NA 11. Combined Control Device Efficiency (%): 

# NA 12. ANIVUAL FUEL USAGE (Coal, oil, wood, natural gas, etc.)-Use additional sheets if necessary. Type of Fuel Used Amount (gal, tons, mmcf/year) % Sulfur %Ash Coal 3,7111.77 tons 2.0 30. Natural Gas 59,581 mmcf neg. NA

## 15- a 

## ~ ~ Form D: Process Information (2 of 3) Facility ID# 2900222 Source ID# ESK-1 Actual Emissions per Pollutant Listed for Source Described Above: Attach calculations and documentation of emission factors or other estimation methods used. "Per Ton" Pollutant: TSP PM-10 SO, NO VOC CO Net Control Efficienc %: N/A N/A N/A N/A N/A N/A Actual Emissions: Tons/ r 46.2 29.26 46.2 19.64 1.08 30.8 ***All Other HAPs/TAPs as listed in Appendix C and Appendix D(use addidonal sheets as necessary)*** 

## Pollutant CAS Number Actual (lb./Year) Comments Antimony NA 2.08 Arsenic NA 10.00 Benzene 71-43-2 22.33 i 

## j Beryllium NA 1.23 Cadium NA 1.16 ; Carbon'Disulfide 75-15-0 0.18 ! Carbon Tetrachloride 56-23-5 0.004 Chlorine 7782-50-5 0 i 

# ~ Chlorobenzene 108-90-7 1.62 Chloroform 67-66-3 0.004 Chromium NA 3.93 Cobalt NA 0.16 

# ~ Dibenzo Furan 132-64-9 0.0028 

# I Dimethylphalate 131-11-3 0.03 Ethyl Benzene 100-41-4 1.62 Fluorine 7782414 0 Hydrazine 302-01-2 0 Hydrogen Chloride 7647-01-0 16,170 Hydrogen Fluoride 7664-39-3 44,660 Hydrogen Sulfide 7783-06-4 0 Isophorone 78-59-1 2.31 Bolded Entries are those pollutants specitically listed by NCDAQ. \\gza\gzn\jobs\21857\fonm\cbckilnd.doc 

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## Form D: Process Information (3 of 3) Facility ID# 

## 2900222 Source ID# 

## ESK-1 ***All Other HAPs/TAPs as listed in Appendix C and Appendix D(use additional sheets as necessary)*** 

# i 

# ~ Pollutant CAS Number Actual (lb./Year) Comments Lead compounds LEADCPDS 11.60 Maganese NA 22.30 Mercury NA 7.39 Methyl Chloroform 71-55-6 0.004 Methylene Chloride 75-09-2 0 Naphthalene 91-20-3 0.77 Nickel NA 5.54 Ozone 10028-15-6 0 Perchloroethylene 127-18-4 0.004 Phenol 108-95-2 4.08 Phosphine 7803-51-2 0 Phosphorous NA 75.50 Selenium NA 17.70 Styrene 100-42-5 0.004 

## Tetrachloroethane 79-34-5 0.004 Toluene 108-88-3 19.25 Trichlorofluoromethane 75-69-4 1.08 Vinyl acetate 108-05-4 0.004 Xylenes (total) 1330-20-1 13.63 I Information requested on Form D cannot be held confidential.

Bolded Entries are those pollutants specifically listed by NCDAQ. \\gzu\gza\jobs\.1357\(orms\cbckilnd.doc 

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## t) ; Process Information (1 of 2) Facility ID # 2900222 North Carolina Ddl&tznent of Environment, Health, and Natural Resources Division of Air Quality Annual Pollutant Emissions Inventory

19 96 

# S R-1 fCe ID No(s). Sand Dryer (E^96rB4) 2. Permit Item No(s). coss Description: Sand is fed into a natural gas-fired rotary:drum and fired to 10-15 percent

~ 

## o content. ional Schedule: Days per Weeks per Hours per 2 Week: 2 ' S year: 49 year: 245 Hour of Process: ;nta e annual throughput: 19 Mar-May 27 June-Aug 27 Sept-Nov 27 mum Process 8. Annual Process Hour: (ex: 6,000 lbs sand/hour Throughput: 1,470,000 lbs sand/year imcf/hr) (ex: lb/yr, gal/yr) ; include units include units 

# E_ ire Efficiency (% of Process Emissions Vented Through Control Device: NA r. 

## tzol Device Descriptions Primary None Secondary None ined Control Device Efficiency (%): NA

~
. 

## WAL FUEL USAGE (Coal, oil, wood, natural gas, etc.)-Use additional sheets if necessary.

~ 

## of Fuel Used Amount (gal, tons, mmcf/year) % Sulfur %Ash tal Gas 666,010 feet 3 (estimated) neg. NA



# 61

## Form D: Process Information (2 of 2) Facility ID# 2900222 Source ID# ESSD-1 _Actual Emissions ner Pollutanf` Eisted for Source Described Above: Attach calculations and documentation of emission factors or other estimation methods used. "Per Ton" Pollutant: TSP PM-10 SO, NO x vOC CO Net Control Efficienc (%): N/A N/A N/A N/A N/A N/A Actual Emissions: Tons/ r 0.74 0.74 .0002 .033 .002 .007 ***All Other HAPs/TAPs as listed in Appendix C and Appendix D(use additional sheets as necessary)*** 

## Pollutant CAS Number Actual (lb./Year) Comments Chlorine 7782-50-5 Fluor9ne 7782414 Hydrazine 302-01-2 

## Hydrogen Chloride 7647-01-0 Hydrogen Fluoride 7664-39-3 Hydrogen Sulfide 7783-064 Lead compounds LEADCPDS Methyl Chloroform 71-55-6 Methylene Chloride 75-09-2 Ozone 10028-15-6 Perchloroethylene 127-184 

## Phenol 108-95-2 Phosphine 7803-51-2 Information requested on Form D cannot be held confidential. 1 r'
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# ~

## C. Using Table 3, please provide information on procedures used to monitor the process operating rate for each of the pieces of equipment and HAP emission - soerces listed in Tables 2A and 2B. Use the same HAP emission source types and equipment ID numbers you listed in Tables 2A to 2B. Indicate whether you monitor process rate or not. Provide a summary of process rate monitoring procedures that describes how process rate is measured for the particular piece of equipment. Include where the rate is monitored (i.e., rate of material fed, rate of material discharged, or material production rate), the units used to measure process rate (e.g, lb/hr or pieces/hr), and how the process data is recorded, i.e., manually, automatically (e.g., computer - printout or stored to disk, or not at all). If you monitor process rate at both the feed and discharge ends of the equipment, indicate so. Indicate the type of monitor, equipment, or instrument used to measure process operating rate. Indicate the monitoring frequency or how often process rate measurements are made. If instruments are used to measure process throughput, indicate in the monitor accuracy column the accuracy of the instrument. The monitor accuracy could be listed in terms of a percentage of the throughput (± 1 percent), mass per unit time (±21b/hr), number of pieces per unit time (± 10 pieces/hr), or other appropriate units. Indicate the frequency that the monitor is calibrated. Provide data in the units listed for each row.

Page 12 of 28 

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## VI. Identification of Brick and Structural Clav Product Manufacturing Emission Points A.
- Use"the process flow diagrams developed for your facility and Table 4 to provide the following information for each HAP emission source at your facility. • Define HAP emission source type in terms of equipment, such as dryers, kilns, etc. As in the process flow diagram, you may group multiple pieces of similar equipment. • Use the same equipment ID numbers indicated on the process flow diagram(s). • If the emission source vents inside a building or to outside ambient air without first passing through a control device, place a check mark in the uncontrolled column. • If the emission source vents inside a building or to outside ambient air after passing through a fabric filter, dry injection fabric filter, or scrubber, place the APCD ID number(s) in the column corresponding to the APCD type. • If the emission source vents through a control device type not listed in Table 4, indicate the control device type in the other control column and place the APCD ID number in the appropriate cell. • In the eniission test data column, place a"yes" or "no" in the appropriate cell to indicate whether the specific source has been tested for Agy pollutants, including any HAP's, VOC, PM, or opacity.

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## Page 14 of 28



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## B. Using Table 5, please provide information on stack parameters and emission estimates for each emission point at your facility that is known or expected to emit -HAI''s. Provide information for all APCD's, including those that exhaust inside the building. Include data for each inlet and outlet, if available, as indicated in the table. If you have more than one inlet to an APCD, provide data for each of the inlets. Provide data in the units h listed for each row. Provide emission estimates for any HAP's or HAP surrogates, such as PM for metal HAP's or VOC for organic HAP's. Emission estimates may consist of measurements reported in emission test reports or may be calculated using mass balances, emission factors, engineering judgement, or other estimation methods. Provide the emission estimates as emission factors in units of lb of pollutant emitted per ton of product (lb/ton). Provide complete copies of any emission test reports or other reports that document measurements of emissions. Test reports and other emission measurement documents should include the following information: process identification; location of sampling point; stack diameter, temperature, and flow rate; test method, including analytical procedures; number of test runs; emission concentration, emission rate, percent oxygen, and percent moisture for each test run; process operating rate; type of APCD; and APCD operating parameters. However, test reports with incomplete documentation may still be useful and should also be submitted. You do not need to fill out Table 5 for emission points that are covered by an emission test report that is included in your submittal. If eniission test reports are not available, provide calculations that support your emission estimate, including the basis for all assumptions in the estimate. Note that emission estimates are needed for all HAP's that the facility emits or has the potential to emit. (Please refer to the HAP list in Attachment 1.) If the information requested in the table is contained in your facility's operating permit, you may reference the applicable sections of the permit rather than filling out the table. 

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## TABLE 1 Summary of Results, Hydrogen Fluoride Sampling

Kiln No. 1 Stack

~ ~ • 

## Run Number 1 2 3 Avg. Date 04/22/97 04/22/97 04/22/97 --- 

## Sample Identification 7031-01 7031-02 7031-0 3 --- Run Duration, Minutes 62.5 62.5 62.5 --- Sample Time, 24-hour clock 0830-0937 0955-1005 1037-1145 --- Percent Isokinetic 101.3 101.0 100.9 101.1 Volume of Gas Sampled, 51.95 54.34 54.42 53.57 dry standard cubic feet*(DSCF) Average Stack Temperature, °F 537.6 534.2 527.9 533.2 Stack Gas Velocity, feet/second 55.1 58.2 57.3 56.9 Stack Gas Flow Rate, 14391 15290 15124 14935 dry standard cubic feet/minute*(DSCF114) Stack Gas Flow Rate. 30562 32258 31743 31521 actual cubic feet/minute(ACFiv1) Hydrogen Fluoride:
A 

## Catch, mg 110.31 114.48 124.04 116.28 

## Concentration, grains/dsct* 0.0327 0.0324 0.0351 0.0334 Emission Rate, lbs/hr 4.03 4.25 4.55 4.28

* 68°F, 29.92 Inches Hg 

# 13 

# ~5~

# SUMMARY OF RESULTS EPA iv1ETHOD 26A Determination of Hydrogen Fluoride Emissions Cunningham Brick Company Thomasville, North Carolina Kiln No. 1 Run Number 1 2 3 Avg Date: 04/22/97 04/22/97 04/22/97 - 

# TT Net Time ot' Test, minutes 62.5 62.5 62.5 - PB Barometric Pressure, in. Hg 28.80 28.87 28-87 28.85 SP Static Pressure, in. Hg -0.035 -0.035 -0.035 -0.035 PS Stack Pressure, Absolute, in. Hg 28.765 28.835 28.835 28.811 VM Actual Meter Volume Sampled, cu. ft. 52.69 55.22 55.77 54.56 DH Avg. Delta H, in. H20 2.5 2.8 2.3 2.7 TM Avg. Gas Meter Temp., Deg. F 58.9 61.5 65.9 62.1 VSTD Volume Sampled at Stand. Cond., cu. ft. 51.95 54.34 54.42 53.57 VW Volume of Water Collected, mI 89.0 92.1 9 3. 7 91.6 VMV Volume of Water Vapor at Std. Cond.; SCF 4.19 4.34 4.41 4.31 Bws Moisture Content of Gas Stream 0.075 0.074 0.075 0.074

~ 

# PMV Percent Moisture in Stack 7.5 7.4 7.5 7.4 MFD Mole Fraction ot' Drv Gas 0.925 0.926 0.925 0.926 P02 Percent Oxygen, Dry 16.4 16.4 16.7 16.5 PCO2 Percent Carbon Dioxide, Dry - 3.0 3.0 2.9 3.0 PCO Percent Carbon Monoxide, Dry 0.0 0.0 0.0 0.0 MD Mole. Wt. Stack Gas, Dry Basis, lb/lb mole 29.137 29.137 29.136 29-137 MW Mole. Wt. Stack Gas. Wet Basis, lb/lb mole 28.306 28.314 28.301 28-307 CP Pitot Tube Constant 0.84 0.84 0.84 0.84 DPS Avg. Sqrt. Delta P, in. H20 0.69 0.73 0.72 0.72 TS Avg. Stack Temp., Deg. F 537.6 534.2 527.9 533.2 VS Avg. Stack Velocity, ft/sec 55.1 58.2 57.3 56.9 AS

- 

# Area Stack, ft2 9.24 9.24 9.24 9.24 

# I..(n

# SUMMARY OF RESULTS EPA METHOD 26A Determination of Hydrogen Fluoride Emissions Cunninaham Brick Company 'fhomasville, North Carolina Kiln No. 1 QS Gas Volume Flow, Dry Std. Cond. CFM QA Actual Gas Volume Flow, CFM QSW Gas Volume Flow, Wet Std. Cond., CFM DN Sample Nozzle Diameter, inches AN Area o• Nozzle, •t2 PERI Percent Isokinetic 14391 15290 15124 14935 30562 32258 31743 31521 15551 16510 16350 16137 0.311 0.309 0.311 0.310 0.00053 0.00052 0.00053 0.00053 101.3 101.0 100.9 101.1 Hydrogen Fluoride Analysis 

# FMF Hydrogen Fluor
- ide Catch, mg CAN Hydrogen Fluoride Concentration, gr/dscf CAT Hydrogen Fluoride Concentration, gr/acf CAW Hydrogen Fluoride Emission Rate, lbs/hr 110.31 114.48 124.04 116.28 0.0327 0.0324 0.0351 0.0334 0.0154 0.0154 0.0167 0.0158 4.03 4.25 4.55 4.28

# SliMMARY OF RESULTS EPA METHOD 26A Determination of Hydrogen Fluoride Emissions Cunningham Brick Company 'Tfiomasville. North Carolina Kiln No. 1 Example Calculations Run 1 Stack Pressure, Absolute, in. Hg PS=PB+SP= 25.765 Volume Sampled at Stand. Cond., cu. t't.

17.647* VM * (PB + DH / 13.6) VSTD = --- ------------------------------------------ ---- = 51.95



# TM + 460 Volume of Water Vapor at Std. Cond., SCF VMV = 0.04709 * VW = 4.19 

# Moisture Content ot Gas Stream

VNI V Bws= ---------------------------------- = 0.075



# VSTD + VMV Percent Moisture in Stack

100 * VMV PMV= --------------------------- = 7.5



# VSTD + VMV Mole Fraction ot' Dry Gas

100 - PMV MFD = -------- -- -------- ----- = 0.925

100 

# Mole. Wt. Stack Gas, Dry Basis, lb/lb mole ' MD = 0.44 * %CO2 + 0.32 * %02 + 0.28 * (100 - %CO2 - %02) = 29.137 

# Mole. Wt. Stack Gas. Wet Basis, lb/lb mole MW — MD *(1 - Bws) + 18.0 * Bws = 28.306 Avg. Stack Velocity, tt/sec (TS + 460) V S= 85.49 * CP * D P S* S Q RT ---------------- --------- = 55.1 (PS * MW)

A-4 

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# SUMMARY OF RESULTS EPA METHOD 26A Determination of Hydrogen Fluoride Emissions Cunningham Brick Company fihomasville, North Carolina Kiln No. 1 Gas Volume Flow, Dry Std. Cond. CFM 1058.82 * VS * AS * PS *(1 - Bws)

~ 

## )S = --------------------------------------------------- _



# TS + 460 Actual Gas Volume Flow, CFM

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## A=VS*AS*60= 

# Jas Volume Flow, Wet Std. Cond., CFM

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## SW = QS "` [1/(1-Bws)] _ k" 

# krea of Nozzle. ft2 kN = ((DN / 2) ^ 2 * 3.14159)/144 = 

# 'ercent Isokinetic

0.0945 * (TS + 460) * VSTD 'ERI = ---------------------------------------- -- --- -- _ 

# ; TT*VS*PS*(1-Bws)*AN

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# 3ydrogen Fluoride Concentration, gr/dscf . At Standard Conditions) :AN = 0.0154 * FMF / VSTD =

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# . r lydrogen Fluoride Emission Rate, lbs/hr At Standard Conditions) :AW = O.00S57 * CAN * QS = 3tandard Conditions 68 Deg. F, 29.92 in. Hg 

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## C. Using Tables 6A through 61), please provide design and operating data for each APCD associated with all dryers, kilns, and any other brick and structural clay products manufacturing source that may emit HAP's. Use Tables 6A to 6C for specific types of APCD's. Use Table 6D for other types of APCD's. When using Table 61), please specify the type of control device and 2 to 4 key design or operating parameters for the device. Provide data in the units listed for each row. If the information requested in ' Tables 6A through 6D is contained in your facility's operating permit, you may reference the applicable sections of the permit rather than filling out the tables.

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# ~ `P

## D. Using Table 7, please provide the following information on current monitoring procedures for each of the control devices listed in Tables 6A to 6D: parameters monitored (e.g., baghouse pressure drop), monitoring frequency, monitoring devices used (e.g., differential pressure transducer, thermocouple), and recordkeeping practices (e.g., manually recorded in log book, continuously recorded by electronic data acquisition system). Describe briefly other operation and maintenance (O&M) procedures for each control device. If the information requested in the table is contained in your facility's operating permit, you may reference the applicable sections of the permit rather than filling out the table. VII. Pollution Prevention Practices for Brick and Structural Clay Products Manufacturing A. Please describe all pollution prevention practices (i.e., process modifications, such as re-use of discarded or rejected materials, or any practice that prevents or reduces the amount of air emissions, or the generation and release of solid waste or wastewater associated with the operation of air pollution controls). If the information requested here is contained in your facility's operating permit, you may reference the applicable sections of the permit rather than providing the information below. iC2GcSLJeJ A"o &.91-1c,4T/o•N 

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## VIII. Information on Processes Other Than Brick and Structural C1atiProducts Manufacturinz



# Processes A. Using Table 8, please identify all other processes or operations at this facility that are not addressed in Items II through VII above and that are potential sources of HAP emissions. Estimate total annual emissions of each HAP emitted by these colocated processes. If the information requested in the table is contained in your facility's operating permit, you may reference the applicable sections of the permit rather than filling out the table.

Page 27 of 28



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## TABLE 8. ESTIMATED ANNUAL HAP EMISSIONS FROM OTHER SOURCE

Process/emission source/SIC Code(s) HAP's emitted ' S 

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SIC If the information requested in the table is contained in your facility's operating permit, you may reference the applicable sections of the permit rather than filling out the table. Page 28 of 28 

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