Hydraulic Press Brick Company (HPBC) owns and operates a lightweight aggregate product manufacturing facility in Brooklyn, Indiana. The facility produces the lightweight aggregate by melting crushed shale (extracted from an adjacent quarry) in its two operating coal-fired rotary kilns (Kiln 4 and Kiln 5). After the kiln product (called clinker) is cooled, it is crushed, screened, and stored on-site in stockpiles. The primary emission sources at the Brooklyn facility are the kilns, whose exhaust is composed of coal combustion products as well as gases and particulate matter released from the raw materials during the melting process. Particulate matter from HPBC?s Kiln 4 is controlled by a wet scrubber while Kiln 5 is controlled by a baghouse. The facility operates under a Title V Operating Permit issued by the Indiana Department of Environmental Management (IDEM).
On May 3, 2013, EPA conducted an inspection of the Brooklyn, Indiana facility. On August 16, 2013, EPA issued a Request for Information to HPBC under Section 114 of the Act. This information request required HPBC conduct stack testing of the rotary kiln exhaust streams as well as to provide detailed information on the kiln raw materials and final products. HPBC responded to the information request on October 18, 2013 (non-stack test data) and on January 15, 2014 (stack test results).
EPA determined, through both mass balance and stack testing methodologies, that sulfur dioxide (SO2) emissions from HPBC?s Ki