# MAJOR SOURCE OPERATING PERMIT

Permittee: IIG Mineral Wool LLC
Facility Name: IIG Mineral Wool LLC
Facility No.: 211-0013
Location: Phenix City, Alabama

In accordance with and subject to the provisions of the Alabama Air Pollution Control Act of 1971, as amended, Ala. Code §§22-28-1 to 22-28-23 (1997 Rplc. Vol. and 2006 Cum. Supp.) (the "AAPCA") and the Alabama Environme ntal Management Act, as amended, Ala. Code

§§22-22A-1 to 22-22A-15 (1997 Rplc. Vol. and 2006 Cum. Supp.), and ADEM Admin. Code R.s and regulations adopted th ereunder, and subject further to the conditions set forth in this permit, the Permit tee is hereby authorized to construct, install and use the equipment, device or other arti cle described above. Pursuant to the Clean Air Act of 1990 , all conditions of this permit are federally enforceable by EPA, the Alabama Department of Envir onmental Management, and citizens in general. Those provisions which are no t required under the Clean Air Act of 1990 are considered to be state permit provisions and a re not federally enforceable by EPA and citizens in general. Those provisions are contained in separate sections of this permit.



## Issuance Date: October 27, 2008
Expiration Date: September 24, 2013

Alabama Department of Environmental Management

Page 1 of 492 TABLE OF CONTENTS

GENERAL PERMIT PROVISOS............................ ..................................................4

SUMMARY PAGE FOR RAW MATERIAL RECEIVING AND HANDLIN G ..................21

PROVISOS FOR RAW MATERIAL RECEIVING AND HANDLING... .........................22 Applicability ......................................

................................................... .......................22

Emission Standards.................................

................................................... ................22

Compliance and Performance Test Methods and Procedu res.......................................22

Emission Monitoring ................................

................................................... .................22

Recordkeeping and Reporting Requirements ...........

................................................... .22

SUMMARY PAGE FOR #1 MINERAL WOOL CUPOLA FURNACE AND FIBER FORMATION COLLECTION PROCESS....................... ..........................................23

PROVISOS FOR #1 MINERAL WOOL CUPOLA FURNACE AND FIB ER FORMATION COLLECTION PROCESS....................... ..........................................24 Applicability ......................................

................................................... .......................24

Emission Standards.................................

................................................... ................24

Compliance and Performance Test Methods and Procedu res.......................................25

Emission Monitoring ................................

................................................... .................27

Recordkeeping and Reporting Requirements ...........

................................................... .30

SUMMARY PAGE FOR MINERAL WOOL PROCESS – BOARD LINE . ......................34

PROVISOS FOR MINERAL WOOL PROCESS – BOARD LINE ..... ...........................35 Applicability ......................................

................................................... .......................35

Emission Standards.................................

................................................... ................35
Compliance and Performance Test Methods and Procedu res.......................................36

Emission Monitoring ................................

................................................... .................38

Recordkeeping and Reporting Requirements ...........

................................................... .41

SUMMARY PAGE FOR MINERAL WOOL PROCESS – PIPE INSULA TION LINE.......45

PROVISOS FOR MINERAL WOOL PROCESS – PIPE INSULATION LINE ................463

Applicability ......................................

................................................... .......................46

Emission Standards.................................

................................................... ................46
Compliance and Performance Test Methods and Procedu res.......................................46

Emission Monitoring ................................

................................................... .................46

Recordkeeping and Reporting Requirements ...........

................................................... .47

APPENDIX A .........................................

................................................... ..........48

COMPLIANCE ASSURANCE MONITORING (CAM) .............. ..................................484 

## General Permit Provisos

Federally Enforceable Provisos Regulations

1. Transfer
This permit is not transferable, whether by operati on of law or otherwise, either from one location to another, from one piece of equipment to another, or from one person t o another, except as provided in ADEM Admin. Code R. 335-3- 16-.13(1)(a)5. ADEM Admin. Code R. 335-3-16-.02(6)

2. Renewals
An application for permit renewal shall be submitte d at least six (6) months, but not more than eighteen (18) mon ths, before the date of expiration of this permit.
The source for which this permit is issued shall lo se its right to operate upon the expiration of this permit unles s a timely and complete renewal application has been submitted within the time constraints listed in the previous paragraph. ADEM Admin. Code R. 335-3-16-.12(2)

3. Severability Clause
The provisions of this permit are declared to be se verable and if any section, paragraph, subparagraph, subdiv ision, clause, or phrase of this permit shall be adjudged to be invalid or unconstitutional by any court of compete nt jurisdiction, the judgment shall not affect, impair , or invalidate the remainder of this permit, but shall be confined in its operation to the section, paragraph

, subparagraph, subdivision, clause, or phrase of thi s permit that shall be directly involved in the controversy in which such judgment shall have been rendered. ADEM Admin. Code R. 335-3-16-.05(e)

4. Compliance

(a) The permittee shall comply with all conditions of ADEM Admin. Code 335-3. Noncompliance with this permit will constitute a violation of the Clean Air Act of 1990 and ADEM Admin. Code 335-3 and may result in an enforcement action; including but not limited to, permit termination, revocation and reissuance, or modification; or denial of a permit renewal application by the permittee. ADEM Admin. Code R. 335-3-16-.05(f)5 

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(b) The permittee shall not use as a defense in an enforcement action that maintaining compliance with conditions of this permit would have required halti ng or reducing the permitted activity. ADEM Admin. Code R. 335-3-16-.05(g)

5. Termination for Cause
This permit may be modified, revoked, reopened, and reissued, or terminated for cause. The filing of a request by the permittee for a permit modification, revocation and reissuance, or termination, or of a notification of planned changes or anticipated noncompliance will not stay any permit condition. ADEM Admin. Code R. 335-3-16-.05(h)

6. Property Rights
The issuance of this permit does not convey any pro perty rights of any sort, or any exclusive privilege. ADEM Admin. Code R. 335-3-16-.05(i)

7. Submission of Information

The permittee must submit to the Department, within 30 days or for such other reasonable time as the Depar tment may set, any information that the Department may re quest in writing to determine whether cause exists for mo difying, revoking and reissuing, or terminating this permit or to determine compliance with this permit. Upon receiv ing a specific request, the permittee shall also furnish to the Department copies of records required to be kept by this permit. ADEM Admin. Code R. 335-3-16-.05(j)

8. Economic Incentives, Marketable Permits, and Emissions Trading

No permit revision shall be required, under any app roved economic incentives, marketable permits, emissions trading and other similar programs or processes for changes that are provided for in this permit. ADEM Admin. Code R. 335-3-16-.05(k)

9. Certification of Truth, Accuracy, and Completene ss :
Any application form, report, test data, monitoring data, or compliance certification submitted pursuant to this permit shall contain certification by a responsible offici al of truth, accuracy, and completeness. This certification sha ll state that, based on information and belief formed after reasonable inquiry, the statements and information in the ADEM Admin. Code R. 335-3-16-.07(a)6 

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document are true, accurate and complete. 10. Inspection and Entry
Upon presentation of credentials and other document s as may be required by law, the permittee shall allow a uthorized representatives of the Alabama Department of Environmental Management and EPA to conduct the following: ADEM Admin. Code R. 335-3-16-.07(b)

(a) Enter upon the permittee’s premises where a sou rce is located or emissions-related activity is conduct ed, or where records must be kept pursuant to the conditions of this permit; (b) Review and/or copy, at reasonable times, any re cords that must be kept pursuant to the conditions of thi s permit; (c) Inspect, at reasonable times, this facility’s e quipment (including monitoring equipment and air pollution control equipment), practices, or operations regula ted or required pursuant to this permit; (d) Sample or monitor, at reasonable times, substan ces or parameters for the purpose of assuring complianc e with this permit or other applicable requirements. 11. Compliance Provisions
(a) The permittee shall continue to comply with the applicable requirements with which the company has certified that it is already in compliance. ADEM Admin. Code R. 335-3-16-.07(c)

(b) The permittee shall comply in a timely manner w ith applicable requirements that become effective durin g the term of this permit. 12. Compliance Certification
A compliance certification shall be submitted on or before November 23 rd of each calendar year and shall cover the period between September 25 th of the previous year and September 24 th of the current year. ADEM Admin. Code R. 335-3-16-.07(e)

(a) The compliance certification shall include the following: (1) The identification of each term or condition of this permit that is the basis of the certification;7 

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(2) The compliance status; (3) The method(s) used for determining the compliance status of the source, currently and over the reporting period consistent with ADEM Admin. Code R. 335-3-16-.05(c) (Monitoring and Recordkeeping Requirements); (4) Whether compliance has been continuous or intermittent; (5) Such other facts as the Department may require to determine the compliance status of the source; (b) The compliance certification shall be submitted to:
Alabama Department of Environmental Management Air Division P.O. Box 301463 Montgomery, AL 36130-1463

and to:

Air and EPCRA Enforcement Branch

EPA Region IV 61 Forsyth Street, SW Atlanta, GA 30303 13. Reopening for Cause
Under any of the following circumstances, this perm it will be reopened prior to the expiration of the permit: ADEM Admin. Code R. 335-3-16-.13(5) (a) Additional applicable requirements under the Clean Air Act of 1990 become applicable to the permittee with a remaining permit term of three (3) or more years. Such a reopening shall be completed not lat er than eighteen (18) months after promulgation of the applicable requirement. No such reopening is required if the effective date of the requirement i s later than the date on which this permit is due to expire. (b) Additional requirements (including excess emissions requirements) become applicable to an affected source under the acid rain program. Upon approval by the Administrator, excess emissions offset plans8 

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shall be deemed to be incorporated into this permit

. (c) The Department or EPA determines that this permit contains a material mistake or that inaccurate statements were made in establishing the emissions standards or other terms or conditions of this perm it. (d) The Administrator or the Department determines that this permit must be revised or revoked to assure compliance with the applicable requirements. 14. Additional ADEM Admin. Code R.s and Regulations
This permit is issued on the basis of ADEM Admin. C ode R.s and Regulations existing on the date of issuance. In the event additional ADEM Admin. Code R.s and Regulatio ns are adopted, it shall be the permit holder’s respon sibility to comply with such ADEM Admin. Code R.s. §22-28-16(d), Code of Alabama 1975, as amended

15. Equipment Maintenance or Breakdown

(a) In the case of shutdown of air pollution control equipment (which operates pursuant to any permit issued by the Director) for necessary scheduled maintenance, the intent to shut down such equipment shall be reported to the Director at leas t twenty-four (24) hours prior to the planned shutdown, unless such shutdown is accompanied by the shutdown of the source which such equipment is intended to control. Such prior notice shall inclu de, but is not limited to the following: ADEM Admin. Code R. 335-3-1-.07(1), (2)

(1) Identification of the specific facility to be taken out of service as well as its location and permit number; (2) The expected length of time that the air pollution control equipment will be out of service; (3) The nature and quantity of emissions of air contaminants likely to occur during the shutdown period; (4) Measures such as the use of off-shift labor and equipment that will be taken to minimize the length of the shutdown period; (5) The reasons that it would be impossible or impractical to shut down the source operation9 

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during the maintenance period. (b) In the event that there is a breakdown of equipment or upset of process in such a manner as to cause, o r is expected to cause, increased emissions of air contaminants which are above an applicable standard, the person responsible for such equipment shall notify the Director within 24 hours or the ne xt working day and provide a statement giving all pertinent facts, including the estimated duration o f the breakdown. The Director shall be notified when the breakdown has been corrected. 16. Operation of Capture and Control Devices

All air pollution control devices and capture syste ms for which this permit is issued shall be maintained and operated at all times in a manner so as to minimize the emissions of air contaminants. Procedures for ensu ring that the above equipment is properly operated and mainta ined so as to minimize the emission of air contaminants sha ll be established. §22-28-16(d), Code of Alabama 1975, as amended

17. Obnoxious Odors

This permit is issued with the condition that, shou ld obnoxious odors arising from the plant operations b e verified by Air Division inspectors, measures to ab ate the odorous emissions shall be taken upon a determinati on by the Alabama Department of Environmental Management that these measures are technically and economicall y feasible. ADEM Admin. Code R. 335-3-1-.08

18. Fugitive Dust

(a) Precautions shall be taken to prevent fugitive dust emanating from plant roads, grounds, stockpiles, screens, dryers, hoppers, ductwork, etc. ADEM Admin. Code R. 335-3-4-.02

(b) Plant or haul roads and grounds will be maintained in the following manner so that dust will not becom e airborne. A minimum of one, or a combination, of t he following methods shall be utilized to minimize airborne dust from plant or haul roads and grounds: (1) By the application of water any time the surface of the road is sufficiently dry to allow the creation of dust emissions by the act of10 

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wind or vehicular traffic; (2) By reducing the speed of vehicular traffic to a point below that at which dust emissions are created;

(3) By paving;

(4) By the application of binders to the road surface at any time the road surface is found to allow the creation of dust emissions;

Should one, or a combination, of the above methods fail to adequately reduce airborne dust from plant or haul roads and grounds, alternative methods shall be employed, either exclusively or in combination with one or all of th e above control techniques, so that dust will not become ai rborne. Alternative methods shall be approved by the Depart ment prior to utilization.

19. Additions and Revisions
Any modifications to this source shall comply with the modification procedures in ADEM Admin. Code R.s 335 -3- 16-.13 or 335-3-16-.14. ADEM Admin. Code R. 335-3-16-.13 and .14

20. Recordkeeping Requirements

(a) Records of required monitoring information of the source shall include the following: ADEM Admin. Code R. 335-3-16-.05(c)2.
(1) The date, place, and time of all sampling or measurements;
(2) The date analyses were performed;
(3) The company or entity that performed the analyses;
(4) The analytical techniques or methods used;
(5) The results of all analyses; and

(6) The operating conditions that existed at the time of sampling or measurement.11 

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(b) Retention of records of all required monitoring dat a and support information of the source for a period of at least 5 years from the date of the monitoring sample, measurement, report, or application. Support information includes all calibration and maintenance records and all original strip-chart recordings for continuous monitoring instrumentation and copies of all reports required by the permit. 21. Reporting Requirements
(a) Reports to the Department of any required monit oring shall be submitted at least every 6 months. All instances of deviations from permit requirements must be clearly identified in said reports. All re quired reports must be certified by a responsible official consistent with ADEM Admin. Code R. 335-3-16- .04(9). ADEM Admin. Code R. 335-3-16-.05(c)3.

(b) Deviations from permit requirements shall be reported within 48 hours or 2 working day of such deviations, including those attributable to upset conditions as defined in the permit. The report wil l include the probable cause of said deviations, and any corrective actions or preventive measures that were taken.
22. Emission Testing Requirements
Each point of emission which requires testing will be provided with sampling ports, ladders, platforms, a nd other safety equipment to facilitate testing performed in accordance with procedures established by Part 60 o f Title 40 of the Code of Federal Regulations, as the same may be amended or revised. ADEM Admin. Code R. 335-3-1-.05(3) and ADEM Admin. Code R. 335-3-1-.04(1)

The Air Division must be notified in writing at lea st 10 days in advance of all emission tests to be conducted an d submitted as proof of compliance with the Departmen t’s air pollution control ADEM Admin. Code R.s and regulati ons.
To avoid problems concerning testing methods and procedures, the following shall be included with th e12 

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notification letter:

(1) The date the test crew is expected to arrive, t he date and time anticipated of the start of the first run, how many and which sources are to be tested, and the names of the persons and/or testing company that will conduct the tests. ADEM Admin. Code R. 335-3-1-.04

(2) A complete description of each sampling train t o be used, including type of media used in determining gas stream components, type of probe lining, type o f filter media, and probe cleaning method and solvent to be used (if test procedures require probe cleani ng).
(3) A description of the process(es) to be tested i ncluding the feed rate, any operating parameters used to control or influence the operations, and the rated capacity.
(4) A sketch or sketches showing sampling point locations and their relative positions to the neare st upstream and downstream gas flow disturbances.
A pretest meeting may be held at the request of the source owner or the Air Division. The necessity for such a meeting and the required attendees will be determined on a case-bycase basis.

All test reports must be submitted to the Air Divis ion within 30 days of the actual completion of the test unless an extension of time is specifically approved by the A ir Division. ADEM Admin. Code R.

335-3-1-.04

23. Payment of Emission Fees
Annual emission fees shall be remitted each year ac cording to the fee schedule in ADEM Admin. Code R. 335-1-7- .04. ADEM Admin. Code R. 335-1-7-.04
24. Other Reporting and Testing Requirements
Submission of other reports regarding monitoring re cords, fuel analyses, operating rates, and equipment malfu nctions may be required as authorized in the Department's a ir pollution control ADEM Admin. Code R.s and regulati ons. The Department may require emission testing at any time. ADEM Admin. Code R. 335-3-1-.04(1)13 

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25. Title VI Requirements (Refrigerants )
Any facility having appliances or refrigeration equ ipment, including air conditioning equipment, which use Cla ss I or Class II ozone-depleting substances as listed in 40 CFR Part 82, Subpart A, Appendices A and B, shall service, r epair, and maintain such equipment according to the work practices, personnel certification requirements, an d certified recycling and recovery equipment specified in 40 CF R Part 82, Subpart F. No person shall knowingly vent or otherwise release any Class I or Class II substance into the environment during the repair, servicing, maintenance, or disposal of any device except as provided in 40 CFR Part 82, Subpart F. The responsible official shall comply with all repo rting and recordkeeping requirements of 40 CFR 82.166. Repor ts shall be submitted to the US EPA and the Department as required. 40 CFR 82

26. Chemical Accidental Prevention Provisions

If a chemical listed in Table 1 of 40 CFR Part 68.1 30 is present in a process in quantities greater than the threshold quantity listed in Table 1, then: (a) The owner or operator shall comply with the provisions in 40 CFR Part 68. (b) The owner or operator shall submit one of the following: (1) A compliance schedule for meeting the requirements of 40 CFR Part 68 by the date provided in 40 CFR Part 68 § 68.10(a) or, (2) A certification statement that the source is in compliance with all requirements of 40 CFR Part 68, including the registration and submission of the Risk Management Plan. 40 CFR Part 68

27. Display of Permit
This permit shall be kept under file or on display at all times at the site where the facility for which the permit is issued is located and will be made readily available for insp ection by ADEM Admin. Code R. 335-3-14-.01(1)(d)14 

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any or all persons who may request to see it.

28. Circumvention

No person shall cause or permit the installation or use of any device or any means which, without resulting in reduction in the total amount of air contaminant em itted, conceals or dilutes any emission of air contaminant which would otherwise violate the Division 3 ADEM Admin. Code R.s and regulations. ADEM Admin. Code R. 335-3-1-.10

29. Visible Emissions
Unless otherwise specified in the Unit Specific pro visos of this permit, any source of particulate emissions sh all not discharge more than one 6-minute average opacity gr eater than 20% in any 60-minute period. At no time shall any source discharge a 6-minute average opacity of part iculate emissions greater than 40%. Opacity will be determ ined by 40 CFR Part 60, Appendix A, Method 9, unless otherw ise specified in the Unit Specific provisos of this per mit. ADEM Admin. Code R. 335-3-4-.01(1)

30. Fuel-Burning Equipment
(a) Unless otherwise specified in the Unit Specific provisos of this permit, no fuel-burning equipment may discharge particulate emissions in excess of th e emissions specified in Part 335-3-4-.03.
(b) Unless otherwise specified in the Unit Specific provisos of this permit, no fuel-burning equipment may discharge sulfur dioxide emissions in excess of the emissions specified in Part 335-3-5-.01. ADEM Admin. Code R. 335-3-4-.03

ADEM Admin. Code R. 335-3-5-.01

31. Process Industries – General
Unless otherwise specified in the Unit Specific pro visos of this permit, no process may discharge particulate e missions in excess of the emissions specified in Part 335-3- 4-.04. ADEM Admin. Code R. 335-3-4-.04

32. Averaging Time for Emission Limits
Unless otherwise specified in the permit, the avera ging time for the emission limits listed in this permit shall be the ADEM Admin. Code R.15 

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nominal time required by the specific test method. 335-3-1-.05

33. Compliance Assurance Monitoring (CAM) 40 CFR 64
Conditions (a) through (d) that follow are general conditions applicable to emissions units that are subject to t he CAM requirements. Specific requirements related to eac h emissions unit are contained in the unit specific p rovisos and the attached CAM appendices.

(a) Operation of Approved Monitoring 40 CFR 64.7

(1) Commencement of operation . The owner or operator shall conduct the monitoring required under this section and detailed in the unit specific provisos and CAM appe ndix of this permit (if required) upon issuance of the perm it, or by such later date specified in the permit pursuant to §64.6(d).

(2) Proper maintenance . At all times, the owner or operator shall maintain the monitoring, including but not limited to, maintaining necessary parts for routine repairs of the monitoring equipment.

(3) Continued operation . Except for, as applicable, monitoring malfunctions, associated repairs, and required qual ity assurance or control activities (including, as appl icable, calibration checks and required zero and span adjustments), the owner or operator shall conduct a ll monitoring in continuous operation (or shall collec t data at all required intervals) at all times that the pollu tant-specific emissions unit is operating. Data recorded during monitoring malfunctions, associated repairs, and re quired quality assurance or control activities shall not b e used for purposes of this part, including data averages and calculations, or fulfilling a minimum data availabi lity requirement, if applicable. The owner or operator s hall use all the data collected during all other periods in assessing the operation of the control device and associated control system. A monitoring malfunction is any sudden, infrequent, not reasonably preventable failure of t he monitoring to provide valid data. Monitoring failur es that are caused in part by poor maintenance or careless oper ation16 

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are not malfunctions.

(4) Response to excursions or exceedances . (a) Upon detecting an excursion or exceedance, the owner or operator s hall restore operation of the pollutant-specific emissio ns unit (including the control device and associated captur e system) to its normal or usual manner of operation as exped itiously as practicable in accordance with good air pollutio n control practices for minimizing emissions. The response sh all include minimizing the period of any startup, shutd own or malfunction and taking any necessary corrective act ions to restore normal operation and prevent the likely rec urrence of the cause of an excursion or exceedance (other t han those caused by excused startup or shutdown conditions). Such actions may include initial inspection and evaluati on, recording that operations returned to normal withou t operator action (such as through response by a computerized distribution control system), or any n ecessary follow-up actions to return operation to within the indicator range, designated condition, or below the applicabl e emission limitation or standard, as applicable. ( b) Determination of whether the owner or operator ha s used acceptable procedures in response to an excursion o r exceedance will be based on information available, which may include but is not limited to, monitoring resul ts, review of operation and maintenance procedures and records , and inspection of the control device, associated captur e system, and the process.

(5) Documentation of need for improved monitoring . After approval of monitoring under this part, if the owne r or operator identifies a failure to achieve compliance with an emission limitation or standard for which the appro ved monitoring did not provide an indication of an excu rsion or exceedance while providing valid data, or the resul ts of compliance or performance testing document a need t o modify the existing indicator ranges or designated conditions, the owner or operator shall promptly no tify the Department and, if necessary, submit a proposed modification to the permit to address the necessary monitoring changes. Such a modification may include , but is not limited to, reestablishing indicator ranges or designated conditions, modifying the frequency of17 

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conducting monitoring and collecting data, or the monitoring of additional parameters.

(b) Quality Improvement Plan (QIP) Requirements 40 CFR 64.8

(1) Based on the results of a determination made under Section 33(a)(4)(b) above, the Administrator or the permitt ing authority may require the owner or operator to deve lop and implement a QIP. Consistent with 40 CFR §64.6(c)(3) , the permit may specify an appropriate threshold, such a s an accumulation of exceedances or excursions exceeding 5 percent duration of a pollutant-specific emissions unit's operating time for a reporting period, for requirin g the implementation of a QIP. The threshold may be set a t a higher or lower percent or may rely on other criter ia for purposes of indicating whether a pollutant-specific emissions unit is being maintained and operated in a manner consistent with good air pollution control p ractices.

(2) Elements of a QIP:

(a) The owner or operator shall maintain a written QIP, if required, and have it available for inspection.

(b) The plan initially shall include procedures for evaluating the control performance problems and, based on the results of the evaluation procedures, the owner or operator shall modify the plan to include procedures for conducting one or more of the following actions, as appropriate:

i. Improved preventive maintenance practices.

ii. Process operation changes.

iii. Appropriate improvements to control methods.

iv. Other steps appropriate to correct control performance.

v. More frequent or improved monitoring (only in conjunction with one or more steps under18 

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paragraphs (2)(b)(i) through (iv) above).

(3) If a QIP is required, the owner or operator shall d evelop and implement a QIP as expeditiously as practicable and shall notify the Department if the period for completing the improvements contained in the QIP exceeds 180 days from the date on which the need to implement the QIP was determined.

(4) Following implementation of a QIP, upon any subsequ ent determination pursuant to Section 33(a)(4)(b) above , the Department may require that an owner or operator ma ke reasonable changes to the QIP if the QIP is found t o have:

(a) Failed to address the cause of the control device performance problems; or

(b) Failed to provide adequate procedures for correcting control device performance problems as expeditiously as practicable in accordance with good air pollution control practices for minimizing emissions.

(5) Implementation of a QIP shall not excuse the owner or operator of a source from compliance with any exist ing emission limitation or standard, or any existing mo nitoring, testing, reporting or recordkeeping requirement tha t may apply under federal, state, or local law, or any ot her applicable requirements under the Act.

(c) Reporting and Recordkeeping Requirements 40 CFR 64.9

(1) General reporting requirements

(a) On and after the date specified in Section 33(a)(1) above by which the owner or operator must use monitoring that meets the requirements of this part, the owner or operator shall submit monitoring reports to the permitting authority in accordance with ADEM Admin. Code R. 335-3- 16-.05(c)3.19 

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(b) A report for monitoring under this part shall include, at a minimum, the information required under ADEM Admin. Code R. 335-3-16-.05(c)3. and the following information, as applicable:

i. Summary information on the number, duration and cause (including unknown cause, if applicable) of excursions or exceedances, as applicable, and the corrective actions taken;

ii. Summary information on the number, duration and cause (including unknown cause, if applicable) for monitor downtime incidents (other than downtime associated with zero and span or other daily calibration checks, if applicable); and

iii. A description of the actions taken to implement a QIP during the reporting period as specified in Section 33(b) above. Upon completion of a QIP, the owner or operator shall include in the next summary report documentation that the implementation of the plan has been completed and reduced the likelihood of similar levels of excursions or exceedances occurring.

(2) General recordkeeping requirements.

(a) The owner or operator shall comply with the recordkeeping requirements specified in ADEM Admin. Code R. 335-3-16-.05(c)2.. The owner or operator shall maintain records of monitoring data, monitor performance data, corrective actions taken, any written quality improvement plan required pursuant to Section 33(b) above and any activities undertaken to implement a quality improvement plan, and other supporting information required to be maintained under this part (such as data used to document the adequacy of monitoring, or records of monitoring maintenance or corrective actions). (b) Instead of paper records, the owner or operator may maintain records on alternative media, such as microfilm, computer files, magnetic tape disks, or microfiche, provided that the use of20 

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such alternative media allows for expeditious inspection and review, and does not conflict with other applicable recordkeeping requirements. (d) Savings Provisions 40 CFR 64.10

(1) Nothing in this part shall:

a. Excuse the owner or operator of a source from compliance with any existing emission limitation or standard, or any existing monitoring, testing, repo rting or recordkeeping requirement that may apply under federal, state, or local law, or any other applicab le requirements under the Act. The requirements of thi s part shall not be used to justify the approval of monitoring less stringent than the monitoring which is required under separate legal authority and are not intended to establish minimum requirements for the purpose of determining the monitoring to be imposed under separate authority under the Act, including monitoring in permits issued pursuant to title I of the Act. The purpose of this part is to require, as par t of the issuance of a permit under title V of the Act, impr oved or new monitoring at those emissions units where monitoring requirements do not exist or are inadequ ate to meet the requirements of this part.
b. Restrict or abrogate the authority of the Departmen t to impose additional or more stringent monitoring, recordkeeping, testing, or reporting requirements o n any owner or operator of a source under any provision of the Act, including but not limited to sections 114(a)(1) and 504(b), or state law, as applicable.

c. Restrict or abrogate the authority of the Departmen t to take any enforcement action under the Act for an y violation of an applicable requirement or of any person to take action under section 304 of the Act.21



## Summary Page for Raw Material Receiving and Handlin g

Permitted Operating Schedule: 24 Hrs/day x 7 Days/week x 52 Weeks/yr = 8760 Hrs/yr

Emission limitations:

Emission Point # Description Pollutant Emission limit Regulation

F-001 Raw Material Receiving and Handling PM N/A N/A22



## Provisos for Raw Material Receiving and Handling

Federally Enforceable Provisos Regulations

Applicability

1. These units are subject to the applicable requireme nts of ADEM Admin. Code R. 335-3-16-.03, “ Major Source Operating Permits ”. ADEM Admin. Code R. 335-3-16-.03

2. These units are subject to ADEM Admin. Code R. 335- 3-4-.02,

“ Fugitive Dust and Fugitive Emissions ”. ADEM Admin. Code R. 335-3-4-.02

Emission Standards

1. There are no unit specific emissions standards whic h apply to this process. N/A

Compliance and Performance Test Methods and Procedu res

1. There are no unit specific compliance and performan ce test methods or procedures which apply to this process. N/A

Emission Monitoring

1. There are no unit specific emissions monitoring req uirements which apply to this process. N/A

Recordkeeping and Reporting Requirements

1. There are no unit specific recordkeeping and report ing requirements which apply to this process. N/A23



## Summary Page for #1 Mineral Wool Cupola Furnace and

Fiber Formation Collection Process

Permitted Operating Schedule: 24 Hrs/day x 7 Days/week x 52 Weeks/yr = 8760 Hrs/yr

Emission limitations:

Emission Point # Description Pollutant Emission limit Regulation 101 Environtech #1, Filterhouse #1 PM 117 lb/hr BAC T 101 Environtech #1, Filterhouse #1 CO 17.0 lb/hr An ti-PSD 101 Environtech #1, Filterhouse #1 NO x 15.0 lb/hr BACT 101 Environtech #1, Filterhouse #1 H2S 1.0 lb/hr BA CT 102 Environtech #2 PM 117 lb/hr BACT24



## Provisos for #1 Mineral Wool Cupola Furnace and Fib er

Formation Collection Process

Federally Enforceable Provisos Regulations

Applicability

1. The cupola furnace and fiber collection are subject to the applicable requirements of ADEM Admin. Code R. 335- 3-16- .03, “ Major Source Operating Permits ”. ADEM Admin. Code R. 335-3-16-.03

2. The cupola furnace and fiber collection are subject to ADEM Admin. Code R. 335-3-4-.01(1), “ Control of Particulate Emissions – Visible Emissions ” ADEM Admin. Code R. 335-3-4-.01(1)

3. The cupola furnace has enforceable limits in place in order to comply with the applicable provisions of ADEM Admin . Code R. 335-3-14-.04. “ Air Permits Authorizing Construction in Clean Air Areas [Prevention of Significant Deterioration] ”. ADEM Admin. Code R. 335-3-14-.04

4. The cupola is subject to the applicable requirement s of 40 CFR 63 Subpart DDD, “ National Emission Standards for Hazardous Air Pollutants for Mineral Wool Production ”. ADEM Admin. Code R. 335-3-11-.06(55) [§ 63.1178]
5. The cupola is subject to the applicable requirement s of 40 CFR 63 Subpart A, “ General Provisions ”, as listed in Table 1 in Subpart DDD in 40 CFR Part 63. ADEM Admin. Code R. 335-3-11-.06(55) [§ 63.1178]

6. This cupola is subject to 40 CFR 64, “ Compliance Assurance Monitoring.” Pre-control potential carbon monoxide emissions exceed 100 TPY. 40 CFR Part 64

Emission Standards

1. Visible emissions (VE) these units shall not excee d the opacity limitations as specified in General Proviso No. 29. ADEM Admin. Code R. 335-3-4-.01(1)

2. The combined particulate matter (PM) emissions from the Cupola, Fiber Formation/Collection Process, Mineral Wool Process (Board Line), and Mineral Wool Process (Pip e Insulation Line) shall not exceed 117.0 (lb/hr) pou nds per hour. ADEM Admin. Code R. 335-3-14-.04(9)

3. Particulate matter (PM) emissions from each existin g, new, or reconstructed cupola shall not exceed 0.05 kilogram s (kg) of PM per megagram (MG) (0.10 pound [lb] of PM per ton ) of melt. ADEM Admin. Code R. 335-3-11-.06(55) [§63.1178(a)(1)]

4. The Permittee must comply with these standards (Sub part DDD) at all times except during periods of startup, shutdown, or malfunction. ADEM Admin. Code R. 335-3-11-.06(55) [§63.1180]25

Federally Enforceable Provisos Regulations

5. The temperature in the firebox of the thermal oxidi zer on the cupola shall not be less than 1320°F while the cupo la is operating. ADEM Admin. Code R. 335-3-14-.04(9)

6. Sulfur dioxide emissions from the #1 cupola shall n ot exceed 88.5 pounds per hour. ADEM Admin. Code R. 335-3-14-.04(9)

7. Carbon monoxide emissions from the #1 cupola shall not exceed 17.0 pounds per hour. ADEM Admin. Code R. 335-3-14-.04(9)

8. Nitrogen oxides emissions from the #1 cupola shall not exceed 15.0 pounds per hour. ADEM Admin. Code R. 335-3-14-.04(9)

9. Hydrogen sulfide emissions from the #1 cupola shall not exceed 1.0 pounds per hour. ADEM Admin. Code R. 335-3-14-.04(9)

10. Only coke derived from coal shall be used as fuel. Such coke shall not contain sulfur which exceeds 0.7% by weig ht. ADEM Admin. Code R. 335-3-14-.04(9)

11. The cupola shall be vented to a baghouse and an inc inerator in series. ADEM Admin. Code R. 335-3-14-.04(9)

12. The baghouse and incinerator shall not be bypassed during startup or for more than 4 hours during shutdown pe riods. ADEM Admin. Code R. 335-3-14-.04(9)

13. Begin within one hour after the alarm on a bag leak detection system sounds, and complete in a timely manner, cor rective actions as specified in your operations, maintenanc e, and monitoring plan required by §63.1187 of 40 CFR 63 S ubpart DDD. ADEM Admin. Code R. 335-3-11-.06(55) [§63.1178(b)(1)]

14. When the alarm on a bag leak detection system sound s for more than five percent of the total operating time in a sixmonth reporting period, develop and implement a wri tten quality improvement plan (QIP) consistent with the compliance assurance monitoring requirements of §64.8(b)–(d) o f 40 CFR part 64. ADEM Admin. Code R. 335-3-11-.06(55) [§63.1178(b)(2)]

Compliance and Performance Test Methods and Procedu res

1. If testing is required, the nitrogen oxide (NO x ) emissions shall be determined by Methods 7, 7a, 7b, or 7e of 40 CFR 60, Appendix A. ADEM Admin. Code R. 335-3-1-.05

2. If testing is required, the carbon monoxide (CO) em issions shall be determined by Methods 10 or 10b of 40 CFR 60, Appendix A. ADEM Admin. Code R. 335-3-1-.05

3. If testing is required, particulate matter emission s shall be determined by Method 5e of 40 CFR Part 60, Appendix A. ADEM Admin. Code R.

335-3-1-.0526

Federally Enforceable Provisos Regulations

4. If testing is required, the hydrogen sulfide emissi ons shall be determined by Method 11 of 40 CFR Part 60, Appendix A. ADEM Admin. Code R.

335-3-1-.05

5. If testing is required, sulfur dioxide emissions sh all be determined by Methods 6 or 6c of 40 CFR Part 60, Ap pendix A. ADEM Admin. Code R. 335-3-1-.05

6. To comply with the PM standards of Subpart DDD, you must meet all of the following: ADEM Admin. Code R. 335-3-11-.06(55) [§63.1181] (a) Install, adjust, maintain, and continuously operate a bag leak detection system for each fabric filter.

(b) Do a performance test as specified in §63.1188 of t his subpart and show compliance with the PM emission li mits while the bag leak detection system is installed, operational, and properly adjusted.

(c) Begin corrective actions specified in your operatio ns, maintenance, and monitoring plan required by §63.11 87 of this subpart within one hour after the alarm on a b ag leak detection system sounds. Complete the corrective ac tions in a timely manner.

(d) Develop and implement a written QIP consistent with compliance assurance monitoring requirements of 40 CFR 64.8(b) through (d) when the alarm on a bag leak de tection system sounds for more than five percent of the tot al operating time in a six-month reporting period.

7. The performance tests conducted to demonstrate comp liance with the emissions limits in §63.1178 shall conform to the test methods and procedures specified in §63.1188 and §6 3.1189. ADEM Admin. Code R. 335-3-11-.06(55) [§63.1188-1189]

8. Using the results of the performance tests, the fac ility must use the following equation to determine compliance with the PM emission limit: ADEM Admin. Code R. 335-3-11-.06(55) [§63.1190]27

Federally Enforceable Provisos Regulations



### P K Q C E 1



### × ×

=

where:
E = Emission rate of PM, kg/Mg (lb/ton) of melt. C = Concentration of PM, g/dscm (gr/dscf). Q = Volumetric flow rate of exhaust gases, dscm/hr (dscf/hr). K 1 =Conversion factor, 1 kg/1,000 g (1 lb/7,000 gr). P = Average melt rate, Mg/hr (ton/hr).
Emission Monitoring

1. Carbon Monoxide emission monitoring requirements un der 40 CFR Part 64, “ Compliance Assurance Monitoring ” can be found in Appendix A. 40 CFR Part 64

2. A monitoring device that continuously measures and records the firebox temperature of the incinerator on the c upola shall be installed, calibrated, maintained, and operated. ADEM Admin. Code R. 335-3-1-.04

3. Instruments which measure the pressure drop across the filterhouses shall be maintained and operated. ADEM Admin. Code R. 335-3-1-.04

4. During the annual compliance tests, minimum pressur e drops shall be determined for filterhouses. ADEM Admin. Code R. 335-3-1-.04

5. Pressure drop across each filterhouse shall be moni tored and recorded daily, except when the source of pollution to the filterhouse is not being operated. ADEM Admin. Code R. 335-3-1-.04

6. Emissions tests are to be conducted for the followi ng pollutants at intervals not to exceed one year foll owing the date of initial compliance testing. All test reports mus t be submitted to the Department within 15 days of completion of t esting.

Particulate  Carbon Monoxide 
Sulfur Dioxide  ADEM Admin. Code R. 335-3-1-.04

7. A bag leak detection system must meet the following requirements: ADEM Admin. Code R. 335-3-11-.06(55) [§63.1184]28

Federally Enforceable Provisos Regulations

(a) The bag leak detection system must be certified by the manufacturer to be capable of detecting PM emission s at concentrations of 10 milligrams per actual cubic me ter (0.0044 grains per actual cubic foot) or less.

(b) The sensor on the bag leak detection system must pr ovide output of relative PM emissions.

(c) The bag leak detection system must have an alarm th at will sound automatically when it detects an increas e in relative PM emissions greater than a preset level.

(d) The alarm must be located in an area where appropri ate plant personnel will be able to hear it.

(e) For a positive-pressure fabric filter, each compart ment or cell must have a bag leak detector. For a negative- pressure or induced-air fabric filter, the bag leak detector must be installed downstream of the fabric filter. If multi ple bag leak detectors are required (for either type of fab ric filter), detectors may share the system instrumentation and alarm.

(f) Each triboelectric bag leak detection system must b e installed, operated, adjusted, and maintained so th at it follows EPA's ``Fabric Filter Bag Leak Detection Gu idance'' (EPA-454/R-98-015, September 1997). Other bag leak detection systems must be installed, operated, adju sted, and maintained so that they follow the manufacturer 's written specifications and recommendations.
(g) At a minimum, initial adjustment of the system must consist of establishing the baseline output in both of the following ways:

(1) Adjust the range and the averaging period of the de vice.

(2) Establish the alarm set points and the alarm delay time.29

Federally Enforceable Provisos Regulations

(h) After initial adjustment, the range, averaging peri od, alarm set points, or alarm delay time may not be adjusted except as specified in the operations, maintenance, and monitoring plan required by Sec. 63.1187 of this su bpart. In no event may the range be increased by more than 100 percent or decreased by more than 50 percent over a 365 day period unless a responsible official as defined in Sec. 63.2 of the general provisions in subpart A of this part certifies in writing to the Administrator that the fabric filter has been inspected and found to be in good operatin g condition

8. The facility may change control device and process operating parameter levels established during performance tes ts and used to monitor compliance if you do the following: ADEM Admin. Code R. 335-3-11-.06(55) [§63.1186]

(a) The facility must notify the Administrator of your desire to expand the range of a control device or process ope rating parameter level.

(b) Upon approval from the Administrator, the facility must conduct additional performance tests at the propose d new control device or process operating parameter level s. Before operating at these levels, the performance t est results must verify that, at the new levels, the fa cility comply with the emission limits in §§63.1178 and 63 .1179 of subpart DDD.

9. The operations, maintenance, and monitoring plan mu st include the following: ADEM Admin. Code R. 335-3-11-.06(55) [§63.1187(b)]

(a) Process and control device parameters the facility will monitor to determine compliance, along with establi shed operating levels or ranges for each process or cont rol device.

(b) A monitoring schedule.

(c) Procedures for properly operating and maintaining c ontrol devices used to meet the standards in §§63.1178 and 63.1179 of this subpart. These procedures must incl ude an inspection of each incinerator at least once per year. At a minimum, the facility must do the following as pa rt of an incinerator inspection:30

Federally Enforceable Provisos Regulations

(1) Inspect all burners, pilot assemblies, and pilot se nsing devices for proper operation. Clean pilot sensor if necessary.
(2) Ensure proper adjustment of combustion air, and adjust if necessary.

(3) Inspect, when possible, all internal structures (su ch as baffles) to ensure structural integrity per the des ign specifications.

(4) Inspect dampers, fans, and blowers for proper operation.

(5) Inspect motors for proper operation.

(6) Inspect, when possible, combustion chamber refractory lining. Clean, and repair or replace lin ing if necessary.
(7) Inspect incinerator shell for proper sealing, corro sion, and/or hot spots.

(8) For the burn cycle that follows the inspection, document that the incinerator is operating properly and make any necessary adjustments.

(9) Generally observe whether the equipment is maintained in good operating condition.

(10) Complete all necessary repairs as soon as practicab le.

(d) Procedures for keeping records to document complian ce.
(e) Corrective actions the facility will take if proces s or control device parameters vary from the levels established during performance testing.
Recordkeeping and Reporting Requirements

1. Records shall be maintained of the sulfur content o f the coke used in the cupola. ADEM Admin. Code R. 335-3-1-.0431

Federally Enforceable Provisos Regulations

2. A semi-annual monitoring report shall be submitted to the Department according the following schedule: Reporting Period Due Date

March 25 th

to September 24 th

November 23 rd

September 25 th

to March 24 th

May 24 th ADEM Admin. Code 335-3-16-.05(c)(3)

3. A report shall be submitted semi-annually which con tains the following: ADEM Admin. Code R. 335-3-16-.05(c) (a) The periods when firebox temperate in the incinerat or on the cupola was below 1320°F and the corrective acti on taken. (b) The periods when the pressure drops across the filterhouses were below the minimum pressure determ ined during the annual stack tests.

4. All record shall be maintained for a minimum of 5 y ears. ADEM Admin. Code R. 335-3-16-.05(c)2.(ii)
5. This source shall comply with the notification requ irements specified in 63.1191. ADEM Admin. Code R. 335-3-11-.06(55) [§63.1191]

6. The facility must meet the following recordkeeping requirements: ADEM Admin. Code R. 335-3-11-.06(55) [§63.1192] (a) Maintain files of all information required by §63.1 0(b) of the general provisions in subpart A of this part, inclu ding all notifications and reports. (b) Maintain records of the following information also: (1) Cupola production (melt) rate (Mg/hr (tons/hr) of melt). (2) All bag leak detection system alarms. Include the d ate and time of the alarm, when corrective actions were initiated, the cause of the alarm, an explanation o f the corrective actions taken, and when the cause of the alarm was corrected.32

Federally Enforceable Provisos Regulations

(3) Incinerator operating temperature and results of incinerator inspections. For all periods when the average temperature in any three-hour block period fell below the average temperature established duri ng the performance test, and all periods when the inspection identified incinerator components in nee d of repair or maintenance, include the date and time of the problem, when corrective actions were initiated

, the cause of the problem, an explanation of the corrective actions taken, and when the cause of the problem was corrected. (c) Retain each record for at least five years followin g the date of each occurrence, measurement, corrective action, maintenance, record, or report. The most recent two years of records must be retained at the facility. The re maining three years of records may be retained off site. (d) Retain records on microfilm, on a computer, on comp uter disks, on magnetic tape disks, or on microfiche. (e) Report the required information on paper or on a la beled computer disk using commonly available and compatib le computer software.

7. The facility must prepare and submit reports to the Administrator as required by this subpart and §63.1 0 of the general provisions in subpart A of this part. These reports include, but are not limited to, the following: ADEM Admin. Code R. 335-3-11-.06(55) [§63.1193]

(a) A performance test report, as required by §63.10(d) (2) of the general provisions in subpart A of this part, t hat documents the process and control equipment operati ng parameters during the test period, the test methods and procedures, the analytical procedures, all calculat ions, and the results of the performance tests. (b) A startup, shutdown, and malfunction plan, as descr ibed in §63.6(e)(3) of the general provisions in subpart A of this part, that contains specific procedures for operati ng and maintaining the source during periods of startup, shutdown, and malfunction and a program of correcti ve action for malfunctioning process and control syste ms used to comply with the emission standards. In addition to the information required by §63.6(e)(3), the r plan mus t include the following: (1) Procedures to determine and record what caused the malfunction and when it began and ended.33

Federally Enforceable Provisos Regulations

(2) Corrective actions the facility will take if a proc ess or control device malfunctions, including procedures f or recording the actions taken to correct the malfunct ion or minimize emissions.

(3) An inspection and maintenance schedule for each process and control device that is consistent with the manufacturer's instructions and recommendations for routine and long-term maintenance.

(c) A report of each event as required by §63.10(b) of the general provisions in subpart A of this part, inclu ding a report if an action taken during a startup, shutdow n, or malfunction is inconsistent with the procedures in the plan as described in §63.6(e)(3) of the general pro visions in subpart A of this part. (d) An operations, maintenance, and monitoring plan as specified in §63.1187 of this subpart. (e) A semiannual report as required by §63.10(e)(3) of the general provisions in subpart A of this part if mea sured emissions exceed the applicable standard or a monit ored parameter varies from the level established during performance testing. The report must contain the information specified in §63.10(c) of the general p rovisions, as well as the relevant records required by §63.119 2(b) of this subpart. (f) A semiannual report stating that no excess emission s or deviations of monitored parameters occurred during the reporting period as required by §63.10(e)(3)(v) of the general provisions in subpart A of this part if no deviations have occurred.

8. Semi-annual monitoring report required by 40 CFR 63 Subpart DDD shall be submitted to the Department according the following schedule: Reporting Period Due Date

March 25 th

to September 24 th

November 23 rd

September 25 th

to March 24 th

May 24 th ADEM Admin. Code R. 335-3-11-.06(1) [§63.10(a)(5)]34



## Summary Page for Mineral Wool Process – Board Line

Permitted Operating Schedule: 24 Hrs/day x 7 Days/week x 52 Weeks/yr = 8760 Hrs/yr

Emission limitations:

Emission Point # Description Pollutant Emission limit Regulation

102 Filterhouse #3 PM 117 lb/hr BACT

102 Filterhouse #3 CO N/A N/A

102 Filterhouse #3 NOx N/A N/A

102 Filterhouse #3 NH 3 N/A N/A

102 Filterhouse #3 Formaldehyde 0.6 lb/ton of melt § 63.1179(a) 199 Curing Oven Afterburner NH 3 N/A N/A 199 Curing Oven Afterburner Formaldehyde 0.6 lb/ton of melt § 63.1179(a) 199 Curing Oven Afterburner PM N/A N/A 199 Curing Oven Afterburner VOC N/A N/A35



## Provisos for Mineral Wool Process – Board Line

Federally Enforceable Provisos Regulations

Applicability

1. This source is subject to the applicable requiremen ts of ADEM Admin. Code R. 335-3-16-.03, “ Major Source Operating Permits ”. ADEM Admin. Code R. 335-3-16-.03

2. This unit is subject to ADEM Admin. Code R. 335-3-4 -.01(1),

“ Control of Particulate Emissions – Visible Emission s ”. ADEM Admin. Code R. 335-3-4-.01(1)

3. This unit has enforceable limits in place in order to comply with the applicable provisions of ADEM Admin. Code R. 33 5-3-14- .04. “ Air Permits Authorizing Construction in Clean Air A reas [Prevention of Significant Deterioration] ”. ADEM Admin. Code R. 335-3-14-.04

4. A mineral wool production facility is subject to the applicable provisions of 40 CFR 63 Subpart DDD, “ National Emission Standards for Hazardous Air Pollutants for Mineral Wool Production

”. 40 CFR 63 Subpart DDD

5. A mineral wool production facility is subject to the applicable provisions of 40 CFR 63 Subpart A, “ General Provisions ” as listed in Table 1 of 40 CFR 63 Subpart DDD. 40 CFR 63 Subpart DDD

Emission Standards

1. Visible emissions (VE) these units shall not excee d the opacity limitations as specified in General Proviso No. 29. ADEM Admin. Code R. 335-3-4-.01(1)

2. The combined particulate matter (PM) emissions from the Cupola, Fiber Formation/Collection Process, Mineral Wool Process (Board Line), and Mineral Wool Process (Pip e Insulation Line) shall not exceed 117.0 (lb/hr) pou nds per hour. ADEM Admin. Code R. 335-3-14-.04(9)

3. The facility must control emissions from each exist ing, new, or reconstructed curing oven by limiting emissions of formaldehyde to either of the following: ADEM Admin. Code R. 335-3-11-.06(55) [§63.1179(a)] (a) 0.03 kg of formaldehyde per MG (0.06 lb of formalde hyde per ton) of melt or less.

(b) A reduction of uncontrolled formaldehyde emissions by at least 80 percent.

4. The baghouse and incinerator shall not be bypassed during startup or for more than four (4) hours during shut down periods. ADEM Admin. Code 335-3-14-.04(9)

5. Maintain the free-formaldehyde content of each resi n lot and ADEM Admin. Code R.36

Federally Enforceable Provisos Regulations

the formaldehyde content of each binder formulation at or below the specification ranges of the resin and bin der used during the performance test. 335-3-11-.06(55) [§63.1179(b)(1)]

6. Maintain the operating temperature of each incinera tor so that the average operating temperature for each three-ho ur block period never falls below the average temperature es tablished during the performance test. ADEM Admin. Code R. 335-3-11-.06(55) [§63.1179(b)(2)]

7. The Permittee must comply with these standards (Sub part DDD) at all times except during periods of startup, shutdown, or malfunction. ADEM Admin. Code R. 335-3-11-.06(55) [§63.1180]

8. The temperature in the firebox of the afterburner o n the curing oven shall not be less than 1200°F while the curing oven is operating. ADEM Admin. Code 335-3-14-.04(9)

Compliance and Performance Test Methods and Procedu res

1. If testing is required, particulate matter emission s shall be determined by Method 5e of 40 CFR Part 60, Appendix A. ADEM Admin. Code R.

335-3-1-.05

2. To comply with the formaldehyde standards, the faci lity must meet all of the following: ADEM Admin. Code R. 335-3-11-.06(55) [§63.1183] (a) Install, calibrate, maintain, and operate a device that continuously measures the operating temperature in the firebox of each thermal incinerator.

(b) Do a performance test as specified in §63.1188 of t his subpart while manufacturing the product that requir es a binder formulation made with the resin containing t he highest free-formaldehyde content specification ran ge. Show compliance with the formaldehyde emission limi ts while the device for measuring incinerator operatin g temperature is installed, operational, and properly calibrated. Establish the average operating tempera ture as specified in §63.1185(a) of this subpart.

(c) During the performance test that uses the binder formulation made with the resin containing the high est free-formaldehyde content specification range, reco rd the free-formaldehyde content specification range of th e resin used, and the formulation of the binder used, inclu ding the formaldehyde content and binder specification.

(d) Following the performance test, monitor and record the free-formaldehyde content of each resin lot and the formulation of each batch of binder used, including the37

Federally Enforceable Provisos Regulations

formaldehyde content.

(e) Maintain the free-formaldehyde content of each resi n lot and the formaldehyde content of each binder formula tion at or below the specification ranges established du ring the performance test.

(f) Following the performance test, measure and record the average operating temperature of the incinerator as specified in §63.1185(b) of this subpart.
(g) Maintain the operating temperature of the incinerat or so that the average operating temperature for each thr ee-hour block period never falls below the average temperat ure established during the performance test.

(h) Operate and maintain the incinerator as specified i n your operations, maintenance, and monitoring plan requir ed by §63.1187 of this subpart.

(i) With prior approval from the Administrator, the fac ility may do short-term experimental production runs usin g resin where the free-formaldehyde content, or binde r formulations where the formaldehyde content, is hig her than the specification ranges of the resin and bind er used during previous performance tests, or using experim ental pollution prevention process modifications without first doing additional performance tests. Notification of intent to perform a short-term experimental production run mu st include the following information:

(1) The purpose of the experimental run.

(2) The affected production process.

(3) How the resin free-formaldehyde content or binder formulation will deviate from previously approved levels or what the experimental pollution preventio n process modifications are.

(4) The duration of the experimental run.

(5) The date and time of the experimental run.

(6) A description of any emissions testing to be done during the experimental run.

3. The performance tests conducted to demonstrate comp liance ADEM Admin. Code R.38

Federally Enforceable Provisos Regulations

with the emissions limits in §63.1178 shall conform to the test methods and procedures specified in §63.1188 and §6 3.1189. 335-3-11-.06(55) [§63.1188-1189]

4. Using the results of the performance tests, the fac ility must use the following equation to determine compliance with the CO and formaldehyde numerical emission limits: ADEM Admin. Code R. 335-3-11-.06(55) [§63.1190]

6 3 2

1 

### 10 × × × × × ×

= P K K K O MW C E

where:
E = Emission rate of measured pollutant, kg/Mg (lb/ ton) of melt.
C = Measured volume fraction of pollutant, ppm.
MW = Molecular weight of measured pollutant, g/g-mo le:

CO = 28.01, Formaldehyde = 30.03.
Q = Volumetric flow rate of exhaust gases, dscm/hr (dscf/hr).

K 1 = Conversion factor, 1 kg/1,000 g (1 lb/453.6 g).

K 2 = Conversion factor, 1,000 L/m 3 (28.3 L/ft 3 ).

K 3 = Conversion factor, 24.45 L/g-mole.
P = Average melt rate, Mg/hr (ton/hr). Emission Monitoring

1. A monitoring device that continuously measures and records the firebox temperature of the afterburner on the c uring oven shall be installed, calibrated, maintained, and ope rated. ADEM Admin. Code 335-3-14-.04(9)

2. Instruments which measure the pressure drop across the filterhouses shall be maintained and operated. ADEM Admin. Code 335-3-1-.04

3. During the annual compliance test, minimum pressure drops shall be determined for the filterhouses. ADEM Admin. Code 335-3-1-.04

4. Pressure drop across each filterhouse shall be moni tored and recorded daily, except when the source of pollution to the filterhouse is not being operated. ADEM Admin. Code 335-3-1-.04

5. Emissions tests are to be conducted for the followi ng pollutants at intervals not to exceed one year following the d ate of initial compliance testing. All test reports must be submi tted to the ADEM Admin. Code 335-3-1-.0439

Federally Enforceable Provisos Regulations

Department within 15 days of completion of testing.

Particulate  Carbon Monoxides 

Sulfur Dioxide 

6. The following procedures must be done to establish the average operating temperature of the curing oven incinerato r: ADEM Admin. Code R. 335-3-11-.06(55) [§63.1185] (a) During the performance test, the facility must esta blish the average operating temperature of an incinerator as follows:

(1) Continuously measure the operating temperature of the incinerator.

(2) Determine and record the average temperatures in consecutive 15-minute blocks.

(3) Determine and record the arithmetic average of the recorded average temperatures measured in consecutive 15-minute blocks for each of the one-ho ur performance test runs.

(4) Determine and record the arithmetic average of the three one-hour average temperatures during the performance test runs. The average of the three one

hour performance test runs establishes the temperature level to use to monitor compliance.

(b) To comply with the requirements for maintaining the operating temperature of an incinerator after the performance test, the facility must measure and rec ord the average operating temperature of the incinerator as required by §§63.1182 and 63.1183 of this subpart. This average operating temperature of the incinerator is based on the arithmetic average of the one-hour average temperatures for each consecutive three-hour period and is determined in the same manner described in parag raphs (a)(1) through (a)(4) of this section.

7. The facility may change control device and process operating parameter levels established during performance tes ts and used to monitor compliance if you do the following: ADEM Admin. Code R. 335-3-11-.06(55) [§63.1186]

(a) The facility must notify the Administrator of your desire to expand the range of a control device or process ope rating40

Federally Enforceable Provisos Regulations

parameter level.

(b) Upon approval from the Administrator, you must cond uct additional performance tests at the proposed new co ntrol device or process operating parameter levels. Befor e operating at these levels, the performance test res ults must verify that, at the new levels, you comply wit h the emission limits in §§63.1178 and 63.1179 of this su bpart.

8. The operations, maintenance, and monitoring plan mu st include the following: ADEM Admin. Code R. 335-3-11-.06(55) [§63.1187(b)] (a) Process and control device parameters you will moni tor to determine compliance, along with established operat ing levels or ranges for each process or control device

. (b) A monitoring schedule.

(c) Procedures for properly operating and maintaining c ontrol devices used to meet the standards in §§63.1178 and 63.1179 of this subpart. These procedures must incl ude an inspection of each incinerator at least once per year. At a minimum, you must do the following as part of an incinerator inspection:

(1) Inspect all burners, pilot assemblies, and pilot se nsing devices for proper operation. Clean pilot sensor if necessary.
(2) Ensure proper adjustment of combustion air, and adjust if necessary.

(3) Inspect, when possible, all internal structures (su ch as baffles) to ensure structural integrity per the des ign specifications.

(4) Inspect dampers, fans, and blowers for proper operation.

(5) Inspect motors for proper operation.

(6) Inspect, when possible, combustion chamber refractory lining. Clean, and repair or replace lin ing if necessary.
(7) Inspect incinerator shell for proper sealing, corro sion, and/or hot spots.41

Federally Enforceable Provisos Regulations

(8) For the burn cycle that follows the inspection, document that the incinerator is operating properly and make any necessary adjustments.

(9) Generally observe whether the equipment is maintained in good operating condition.

(10) Complete all necessary repairs as soon as practicab le.

(d) Procedures for keeping records to document complian ce.
(e) Corrective actions you will take if process or cont rol device parameters vary from the levels established during performance testing.
Recordkeeping and Reporting Requirements

1. A semi-annual monitoring report shall be submitted to the Department according the following schedule:
Reporting Period Due Date

March 25 th

to September 24 th

November 23 rd

September 25 th

to March 24 th

May 24 th ADEM Admin. Code R. 335-3-16-.05(c)3.

2. A report shall be submitted semi-annually which con tains the following: ADEM Admin. Code R. 335-3-16-.05(c)3.

(a) The periods when the temperature of the afterburner on the curing oven was below 1200 °F and the correctiv e action take;

(b) The periods when the pressure drops across the filterhouses were below the minimum pressure determ ined during the annual stack tests;

3. All record shall be maintained for a minimum of 5 y ears. ADEM Admin. Code R. 335-3-16-.05(c)3.

4. This source shall comply with the notification requ irements specified in 63.1191. ADEM Admin. Code R. 335-3-11-.06(55) [§63.1191]

5. The facility must meet the following recordkeeping requirements: ADEM Admin. Code R. 335-3-11-.06(55) [§63.1191]42

Federally Enforceable Provisos Regulations

(a) Maintain files of all information required by §63.1 0(b) of the general provisions in subpart A of this part, i ncluding all notifications and reports.

(b) Maintain records of the following information also:

(1) All bag leak detection system alarms. Include the d ate and time of the alarm, when corrective actions were initiated, the cause of the alarm, an explanation o f the corrective actions taken, and when the cause of the alarm was corrected.

(2) The free-formaldehyde content of each resin lot and the binder formulation, including formaldehyde content, of each binder batch used in the manufactu re of bonded products.

(3) Incinerator operating temperature and results of incinerator inspections. For all periods when the average temperature in any three-hour block period fell below the average temperature established duri ng the performance test, and all periods when the inspection identified incinerator components in nee d of repair or maintenance, include the date and time of the problem, when corrective actions were initiated

, the cause of the problem, an explanation of the corrective actions taken, and when the cause of the problem was corrected.

(c) Retain each record for at least five years followin g the date of each occurrence, measurement, corrective action, maintenance, record, or report. The most recent two years of records must be retained at the facility. The re maining three years of records may be retained off site.

(d) Retain records on microfilm, on a computer, on comp uter disks, on magnetic tape disks, or on microfiche.

(e) Report the required information on paper or on a la beled computer disk using commonly available and compatib le computer software.

6. The facility must prepare and submit reports to the Administrator as required by this subpart and §63.1 0 of the general provisions in subpart A of this part. These reports include, but are not limited to, the following: ADEM Admin. Code R. 335-3-11-.06(55) [§63.1193]

(a) A performance test report, as required by §63.10(d) (2) of43

Federally Enforceable Provisos Regulations

the general provisions in subpart A of this part, t hat documents the process and control equipment operati ng parameters during the test period, the test methods and procedures, the analytical procedures, all calculat ions, and the results of the performance tests.

(b) A startup, shutdown, and malfunction plan, as descr ibed in §63.6(e)(3) of the general provisions in subpart A of this part, that contains specific procedures for operati ng and maintaining the source during periods of startup, shutdown, and malfunction and a program of correcti ve action for malfunctioning process and control syste ms used to comply with the emission standards. In addi tion to the information required by §63.6(e)(3), your plan must include the following:

(1) Procedures to determine and record what caused the malfunction and when it began and ended.

(2) Corrective actions you will take if a process or co ntrol device malfunctions, including procedures for recording the actions taken to correct the malfunct ion or minimize emissions.

(3) An inspection and maintenance schedule for each process and control device that is consistent with the manufacturer's instructions and recommendations for routine and long-term maintenance.

(c) A report of each event as required by §63.10(b) of the general provisions in subpart A of this part, inclu ding a report if an action taken during a startup, shutdow n, or malfunction is inconsistent with the procedures in the plan as described in §63.6(e)(3) of the general provisio ns in subpart A of this part.

(d) An operations, maintenance, and monitoring plan as specified in §63.1187 of this subpart.

(e) A semiannual report as required by §63.10(e)(3) of the general provisions in subpart A of this part if mea sured emissions exceed the applicable standard or a monit ored parameter varies from the level established during performance testing. The report must contain the information specified in §63.10(c) of the general p rovisions, as well as the relevant records required by §63.119 2(b) of this subpart.44

Federally Enforceable Provisos Regulations

(f) A semiannual report stating that no excess emission s or deviations of monitored parameters occurred during the reporting period as required by §63.10(e)(3)(v) of the general provisions in subpart A of this part if no deviations have occurred.

7. Semi-annual monitoring report required by 40 CFR 63 Subpart DDD shall be submitted to the Department according the following schedule:
Reporting Period Due Date

March 25 th

to September 24 th

November 23 rd

September 25 th

to March 24 th

May 24 th ADEM Admin. Code R. 335-3-11-.06(1) [§63.10(a)(5)]45



## Summary Page for Mineral Wool Process – Pipe Insula tion Line

Permitted Operating Schedule: 24 Hrs/day x 7 Days/week x 52 Weeks/yr = 8760 Hrs/yr

Emission limitations:

Emission Point # Description Pollutant Emission limit Regulation

102 Filterhouse #2 and #3 PM 117 lb/hr BACT

102 Filterhouse #2 and #3 CO N/A N/A

102 Filterhouse #2 and #3 NOx N/A N/A

102 Filterhouse #2 and #3 NH 3 N/A N/A

102 Filterhouse #2 and #3 Formaldehyde 0.6 lb/ton of melt § 63.1179(a)46



## Provisos for Mineral Wool Process – Pipe Insulation Line

Federally Enforceable Provisos Regulations

Applicability

1. This source is subject to the applicable requiremen ts of ADEM Admin. Code R. 335-3-16-.03, “ Major Source Operating Permits ”. ADEM Admin. Code R. 335-3-16-.03

2. This unit is subject to ADEM Admin. Code R. 335-3-4 -.01(1),

“ Control of Particulate Emissions – Visible Emission s ”. ADEM Admin. Code R. 335-3-4-.01(1)

3. This unit has enforceable limits in place in order to comply with the applicable provisions of ADEM Admin. Code R. 33 5-3-14- .04. “ Air Permits Authorizing Construction in Clean Air A reas [Prevention of Significant Deterioration] ”. ADEM Admin. Code R. 335-3-14-.04

Emission Standards

1. Visible emissions (VE) these units shall not excee d the opacity limitations as specified in General Proviso No. 29. ADEM Admin. Code R. 335-3-4-.01(1)

2. The combined particulate matter (PM) emissions from the Cupola, Fiber Formation/Collection Process, Mineral Wool Process (Board Line), and Mineral Wool Process (Pip e Insulation Line) shall not exceed 117.0 (lb/hr) pounds per hou r. ADEM Admin. Code R. 335-3-14-.04(9)

3. The baghouse shall not be bypassed during startup o r for more than four (4) hours during shutdown periods. ADEM Admin. Code 335-3-14-.04(9) Compliance and Performance Test Methods and Procedu res

1. If testing is required, particulate matter emission s shall be determined by Method 5e of 40 CFR Part 60, Appendix A. ADEM Admin. Code R.

335-3-1-.05
Emission Monitoring

1. Instruments which measure the pressure drop across the filterhouses shall be maintained and operated. ADEM Admin. Code 335-3-1-.04

2. During the annual compliance test, minimum pressure drops shall be determined for the filterhouses. ADEM Admin. Code 335-3-1-.04

3. Pressure drop across each filterhouse shall be moni tored and recorded daily, except when the source of pollution to the filterhouse is not being operated. ADEM Admin. Code 335-3-1-.04

4. Particulate matter emissions tests are to be conduc ted at intervals not to exceed one year following the date of initial compliance testing. All test reports must be submi tted to the Department within 15 days of completion of testing. ADEM Admin. Code 335-3-1-.0447

Federally Enforceable Provisos Regulations

Recordkeeping and Reporting Requirements

1. A semi-annual monitoring report shall be submitted to the Department according the following schedule:
Reporting Period Due Date

March 25 th

to September 24 th

November 23 rd

September 25 th

to March 24 th

May 24 th ADEM Admin. Code R. 335-3-16-.05(c)3.

2. A report shall be submitted semi-annually which con tains the following: ADEM Admin. Code R. 335-3-16-.05(c)3.

(a) The periods when the pressure drops across the filterhouses were below the minimum pressure determ ined during the annual stack tests;48 

## APPENDIX A

40 CFR 64

Compliance Assurance Monitoring (CAM)49 MONITORING APPROACH: Cupola Gas-fired Incinerator

Indicator No. 1 Indicator No. 2 I. Indicator Cupola Incinerator Temperature Inspec tion and Maintenance Provisions

Measurement Approach Cupola incinerator temperature will be monitored continuously when the cupola is in operation. Follow procedures in section 63.1187(b)(3) of 40 CFR 63 Subpart DDD II. Indicator Range Cupola incinerator temperature will be maintained at or above 1320oF while the cupola is in operation (excludes startup and shutdown). Follow procedures in section 63.1187(b)(3) of 40 CFR 63 Subpart DDD

III. Performance Criteria

Data Representativeness Cupola incinerator temperature will be monitored with a temperature indicating device installed in the combustion chamber of the incinerator, providing directly representative data. Follow procedures in section 63.1187(b)(3) of 40 CFR 63 Subpart DDD

Verification of Operation Status When operational, cupola incinerator temperature indicator will display the incinerator temperature. Documented completion of inspection and maintenance activities in accordance with section 63.1187(b)(3) of 40 CFR 63 Subpart DDD QA/QC Practices and Criteria Cupola incinerator temperature will be automatically recorded. Persons performing the inspection and maintenance will be trained in proper techniques and provided the proper background to effectively perform the inspection and maintenance Monitoring Frequency Cupola incinerator temperature

is monitored continuously. At least once per year

Data Collection Procedures Automatic. Records of completions of inspection and maintenance Averaging period N/A N/A