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 Environmental 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 thereunder, and subject further to 

the conditions set forth in this permit, the Permittee is hereby authorized to construct, 

install and use the equipment, device or other article described above. 

Pursuant to the Clean Air Act of 1990, all conditions of this permit are federally 

enforceable by EPA, the Alabama Department of Environmental Management, and 

citizens in general. Those provisions which are not required under the Clean Air Act of 

1990 are considered to be state permit provisions and are 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 49 
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TABLE OF CONTENTS 

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

SUMMARY PAGE FOR RAW MATERIAL RECEIVING AND HANDLING ..................21

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

Applicability ................................................................................................................22

Emission Standards....................................................................................................22

Compliance and Performance Test Methods and Procedures.......................................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 FIBER 

FORMATION COLLECTION PROCESS.................................................................24

Applicability ................................................................................................................24

Emission Standards....................................................................................................24

Compliance and Performance Test Methods and Procedures.......................................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 Procedures.......................................36

Emission Monitoring ....................................................................................................38

Recordkeeping and Reporting Requirements ...............................................................41

SUMMARY PAGE FOR MINERAL WOOL PROCESS – PIPE INSULATION LINE.......45

PROVISOS FOR MINERAL WOOL PROCESS – PIPE INSULATION LINE ................46
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Applicability ................................................................................................................46

Emission Standards....................................................................................................46

Compliance and Performance Test Methods and Procedures.......................................46

Emission Monitoring ....................................................................................................46

Recordkeeping and Reporting Requirements ...............................................................47

APPENDIX A ......................................................................................................48

COMPLIANCE ASSURANCE MONITORING (CAM) ................................................48
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General Permit Provisos 

Federally Enforceable Provisos Regulations 

1. Transfer

This permit is not transferable, whether by operation of law 

or otherwise, either from one location to another, from one 

piece of equipment to another, or from one person to 

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 submitted at least 

six (6) months, but not more than eighteen (18) months, 

before the date of expiration of this permit. 

The source for which this permit is issued shall lose its right 

to operate upon the expiration of this permit unless 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 severable 

and if any section, paragraph, subparagraph, subdivision, 

clause, or phrase of this permit shall be adjudged to be 

invalid or unconstitutional by any court of competent 

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 this 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) 
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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 halting 

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 property 

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 Department 

may set, any information that the Department may request 

in writing to determine whether cause exists for modifying, 

revoking and reissuing, or terminating this permit or to 

determine compliance with this permit. Upon receiving 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 approved 

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 Completeness: 

Any application form, report, test data, monitoring data, or 

compliance certification submitted pursuant to this permit 

shall contain certification by a responsible official of truth, 

accuracy, and completeness. This certification shall 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) 
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document are true, accurate and complete. 

10. Inspection and Entry

Upon presentation of credentials and other documents as 

may be required by law, the permittee shall allow authorized 

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 source 

is located or emissions-related activity is conducted, 

or where records must be kept pursuant to the 

conditions of this permit; 

(b) Review and/or copy, at reasonable times, any records 

that must be kept pursuant to the conditions of this 

permit; 

(c) Inspect, at reasonable times, this facility’s equipment 

(including monitoring equipment and air pollution 

control equipment), practices, or operations regulated 

or required pursuant to this permit; 

(d) Sample or monitor, at reasonable times, substances 

or parameters for the purpose of assuring compliance 

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 with 

applicable requirements that become effective during 

the term of this permit. 

12. Compliance Certification

A compliance certification shall be submitted on or before 

November 23rd of each calendar year and shall cover the 

period between September 25th of the previous year and 

September 24th 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;
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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 permit 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 later 

than eighteen (18) months after promulgation of the

applicable requirement. No such reopening is 

required if the effective date of the requirement is 

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 plans
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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 permit. 

(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. Code R.s 

and Regulations existing on the date of issuance. In the 

event additional ADEM Admin. Code R.s and Regulations 

are adopted, it shall be the permit holder’s responsibility 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 least 

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 include, 

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 operation 
9 

General Permit Provisos 

Federally Enforceable Provisos Regulations 

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, or 

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 next 

working day and provide a statement giving all 

pertinent facts, including the estimated duration of 

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 systems 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 ensuring that 

the above equipment is properly operated and maintained so 

as to minimize the emission of air contaminants shall be 

established. 

§22-28-16(d), Code of 

Alabama 1975, as 

amended 

17. Obnoxious Odors

This permit is issued with the condition that, should 

obnoxious odors arising from the plant operations be 

verified by Air Division inspectors, measures to abate the 

odorous emissions shall be taken upon a determination by 

the Alabama Department of Environmental Management 

that these measures are technically and economically 

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 become 

airborne. A minimum of one, or a combination, of the 

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 of 
10 

General Permit Provisos 

Federally Enforceable Provisos Regulations 

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 the above 

control techniques, so that dust will not become airborne. 

Alternative methods shall be approved by the Department 

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. 
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(b) Retention of records of all required monitoring data 

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 monitoring 

shall be submitted at least every 6 months. All 

instances of deviations from permit requirements 

must be clearly identified in said reports. All required 

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 will 

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, and other 

safety equipment to facilitate testing performed in

accordance with procedures established by Part 60 of 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 least 10 days 

in advance of all emission tests to be conducted and 

submitted as proof of compliance with the Department’s air 

pollution control ADEM Admin. Code R.s and regulations. 

To avoid problems concerning testing methods and 

procedures, the following shall be included with the 
12 

General Permit Provisos 

Federally Enforceable Provisos Regulations 

notification letter: 

(1) The date the test crew is expected to arrive, the 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 to be 

used, including type of media used in determining 

gas stream components, type of probe lining, type of 

filter media, and probe cleaning method and solvent

to be used (if test procedures require probe cleaning). 

(3) A description of the process(es) to be tested including 

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 nearest 

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 Division within 

30 days of the actual completion of the test unless an 

extension of time is specifically approved by the Air Division.

ADEM Admin. Code R. 

335-3-1-.04 

23. Payment of Emission Fees

Annual emission fees shall be remitted each year according 

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 records, 

fuel analyses, operating rates, and equipment malfunctions 

may be required as authorized in the Department's air 

pollution control ADEM Admin. Code R.s and regulations. 

The Department may require emission testing at any time. 

ADEM Admin. Code R. 

335-3-1-.04(1) 
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General Permit Provisos 

Federally Enforceable Provisos Regulations 

25. Title VI Requirements (Refrigerants) 

Any facility having appliances or refrigeration equipment, 

including air conditioning equipment, which use Class I or 

Class II ozone-depleting substances as listed in 40 CFR Part 

82, Subpart A, Appendices A and B, shall service, repair, 

and maintain such equipment according to the work 

practices, personnel certification requirements, and certified 

recycling and recovery equipment specified in 40 CFR 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 reporting and 

recordkeeping requirements of 40 CFR 82.166. Reports 

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 68.130 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 inspection by 

ADEM Admin. Code R. 

335-3-14-.01(1)(d) 
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General Permit Provisos 

Federally Enforceable Provisos Regulations 

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 emitted, 

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 provisos of 

this permit, any source of particulate emissions shall not 

discharge more than one 6-minute average opacity greater 

than 20% in any 60-minute period. At no time shall any 

source discharge a 6-minute average opacity of particulate 

emissions greater than 40%. Opacity will be determined by 

40 CFR Part 60, Appendix A, Method 9, unless otherwise 

specified in the Unit Specific provisos of this permit. 

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 the 

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 provisos of 

this permit, no process may discharge particulate emissions 

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 averaging time 

for the emission limits listed in this permit shall be the 

ADEM Admin. Code R. 
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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 the CAM 

requirements. Specific requirements related to each 

emissions unit are contained in the unit specific provisos 

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 appendix of 

this permit (if required) upon issuance of the permit, 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 quality 

assurance or control activities (including, as applicable, 

calibration checks and required zero and span 

adjustments), the owner or operator shall conduct all 

monitoring in continuous operation (or shall collect data at 

all required intervals) at all times that the pollutant-specific 

emissions unit is operating. Data recorded during 

monitoring malfunctions, associated repairs, and required 

quality assurance or control activities shall not be used for 

purposes of this part, including data averages and 

calculations, or fulfilling a minimum data availability 

requirement, if applicable. The owner or operator shall 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 the 

monitoring to provide valid data. Monitoring failures that are 

caused in part by poor maintenance or careless operation 
16 

General Permit Provisos 

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are not malfunctions.

(4) Response to excursions or exceedances. (a) Upon detecting 

an excursion or exceedance, the owner or operator shall 

restore operation of the pollutant-specific emissions unit 

(including the control device and associated capture system) 

to its normal or usual manner of operation as expeditiously 

as practicable in accordance with good air pollution control 

practices for minimizing emissions. The response shall 

include minimizing the period of any startup, shutdown or 

malfunction and taking any necessary corrective actions to 

restore normal operation and prevent the likely recurrence 

of the cause of an excursion or exceedance (other than those 

caused by excused startup or shutdown conditions). Such 

actions may include initial inspection and evaluation, 

recording that operations returned to normal without 

operator action (such as through response by a 

computerized distribution control system), or any necessary 

follow-up actions to return operation to within the indicator 

range, designated condition, or below the applicable 

emission limitation or standard, as applicable. (b) 

Determination of whether the owner or operator has used 

acceptable procedures in response to an excursion or 

exceedance will be based on information available, which 

may include but is not limited to, monitoring results, review 

of operation and maintenance procedures and records, and 

inspection of the control device, associated capture system, 

and the process.

(5) Documentation of need for improved monitoring. After 

approval of monitoring under this part, if the owner or 

operator identifies a failure to achieve compliance with an 

emission limitation or standard for which the approved 

monitoring did not provide an indication of an excursion or 

exceedance while providing valid data, or the results of 

compliance or performance testing document a need to 

modify the existing indicator ranges or designated 

conditions, the owner or operator shall promptly notify 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 of 
17 

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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 permitting 

authority may require the owner or operator to develop and 

implement a QIP. Consistent with 40 CFR §64.6(c)(3), the 

permit may specify an appropriate threshold, such as an 

accumulation of exceedances or excursions exceeding 5 

percent duration of a pollutant-specific emissions unit's 

operating time for a reporting period, for requiring the 

implementation of a QIP. The threshold may be set at a 

higher or lower percent or may rely on other criteria for 

purposes of indicating whether a pollutant-specific

emissions unit is being maintained and operated in a 

manner consistent with good air pollution control practices. 

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

(3) If a QIP is required, the owner or operator shall develop 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 subsequent 

determination pursuant to Section 33(a)(4)(b) above, the 

Department may require that an owner or operator make 

reasonable changes to the QIP if the QIP is found to 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 existing 

emission limitation or standard, or any existing monitoring, 

testing, reporting or recordkeeping requirement that may 

apply under federal, state, or local law, or any other 

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 

General Permit Provisos 

Federally Enforceable Provisos Regulations 

(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 of 
20 

General Permit Provisos 

Federally Enforceable Provisos Regulations 

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, reporting 

or recordkeeping requirement that may apply under 

federal, state, or local law, or any other applicable 

requirements under the Act. The requirements of this 

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 part of the 

issuance of a permit under title V of the Act, improved 

or new monitoring at those emissions units where 

monitoring requirements do not exist or are inadequate 

to meet the requirements of this part. 

b. Restrict or abrogate the authority of the Department 

to impose additional or more stringent monitoring, 

recordkeeping, testing, or reporting requirements on 

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 Department 

to take any enforcement action under the Act for any 

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 Handling 

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/A 
22 

Provisos for Raw Material Receiving and Handling 

Federally Enforceable Provisos Regulations 

Applicability

1. These units 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. 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 which apply to 

this process. 

N/A 

Compliance and Performance Test Methods and Procedures

1. There are no unit specific compliance and performance test 

methods or procedures which apply to this process. 

N/A 

Emission Monitoring

1. There are no unit specific emissions monitoring requirements 

which apply to this process. 

N/A 

Recordkeeping and Reporting Requirements

1. There are no unit specific recordkeeping and reporting 

requirements which apply to this process. 

N/A 
23 

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 BACT 

101 Environtech #1, Filterhouse #1 CO 17.0 lb/hr Anti-PSD 

101 Environtech #1, Filterhouse #1 NOx 15.0 lb/hr BACT 

101 Environtech #1, Filterhouse #1 H2S 1.0 lb/hr BACT 

102 Environtech #2 PM 117 lb/hr BACT 
24 

Provisos for #1 Mineral Wool Cupola Furnace and Fiber 

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 requirements 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 requirements 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 exceed 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 (Pipe 

Insulation Line) shall not exceed 117.0 (lb/hr) pounds per 

hour. 

ADEM Admin. Code R. 

335-3-14-.04(9) 

3. Particulate matter (PM) emissions from each existing, new, or 

reconstructed cupola shall not exceed 0.05 kilograms (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 (Subpart 

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 oxidizer on the 

cupola shall not be less than 1320°F while the cupola is 

operating. 

ADEM Admin. Code R. 

335-3-14-.04(9) 

6. Sulfur dioxide emissions from the #1 cupola shall not 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 weight. 

ADEM Admin. Code R. 

335-3-14-.04(9) 

11. The cupola shall be vented to a baghouse and an incinerator 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 periods. 

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, corrective 

actions as specified in your operations, maintenance, and 

monitoring plan required by §63.1187 of 40 CFR 63 Subpart 

DDD. 

ADEM Admin. Code R. 

335-3-11-.06(55) 

[§63.1178(b)(1)] 

14. When the alarm on a bag leak detection system sounds for 

more than five percent of the total operating time in a sixmonth reporting period, develop and implement a written 

quality improvement plan (QIP) consistent with the compliance 

assurance monitoring requirements of §64.8(b)–(d) of 40 CFR 

part 64. 

ADEM Admin. Code R. 

335-3-11-.06(55) 

[§63.1178(b)(2)] 

Compliance and Performance Test Methods and Procedures

1. If testing is required, the nitrogen oxide (NOx) 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) emissions 

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 emissions shall be 

determined by Method 5e of 40 CFR Part 60, Appendix A. 

ADEM Admin. Code R. 

335-3-1-.05 
26 

Federally Enforceable Provisos Regulations 

4. If testing is required, the hydrogen sulfide emissions 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 shall be 

determined by Methods 6 or 6c of 40 CFR Part 60, Appendix 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 this 

subpart and show compliance with the PM emission limits 

while the bag leak detection system is installed, 

operational, and properly adjusted. 

(c) Begin corrective actions specified in your operations, 

maintenance, and monitoring plan required by §63.1187 of 

this subpart within one hour after the alarm on a bag leak 

detection system sounds. Complete the corrective actions 

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 detection 

system sounds for more than five percent of the total 

operating time in a six-month reporting period. 

7. The performance tests conducted to demonstrate compliance 

with the emissions limits in §63.1178 shall conform to the test 

methods and procedures specified in §63.1188 and §63.1189. 

ADEM Admin. Code R. 

335-3-11-.06(55) 

[§63.1188-1189] 

8. Using the results of the performance tests, the facility 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

C Q K

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). 

K1 =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 under 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 cupola 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 pressure drops 

shall be determined for filterhouses. 

ADEM Admin. Code R. 

335-3-1-.04 

5. Pressure drop across each filterhouse shall be monitored 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 following 

pollutants at intervals not to exceed one year following the date 

of initial compliance testing. All test reports must be submitted 

to the Department within 15 days of completion of testing. 

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 emissions at 

concentrations of 10 milligrams per actual cubic meter 

(0.0044 grains per actual cubic foot) or less. 

(b) The sensor on the bag leak detection system must provide 

output of relative PM emissions. 

(c) The bag leak detection system must have an alarm that 

will sound automatically when it detects an increase in 

relative PM emissions greater than a preset level. 

(d) The alarm must be located in an area where appropriate 

plant personnel will be able to hear it. 

(e) For a positive-pressure fabric filter, each compartment 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 multiple bag 

leak detectors are required (for either type of fabric filter), 

detectors may share the system instrumentation and 

alarm. 

(f) Each triboelectric bag leak detection system must be 

installed, operated, adjusted, and maintained so that it 

follows EPA's ``Fabric Filter Bag Leak Detection Guidance'' 

(EPA-454/R-98-015, September 1997). Other bag leak 

detection systems must be installed, operated, adjusted, 

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 device.

(2) Establish the alarm set points and the alarm delay 

time. 
29 

Federally Enforceable Provisos Regulations 

(h) After initial adjustment, the range, averaging period, 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 subpart. 

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 operating 

condition 

8. The facility may change control device and process operating 

parameter levels established during performance tests 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 operating 

parameter level. 

(b) Upon approval from the Administrator, the facility must 

conduct additional performance tests at the proposed new 

control device or process operating parameter levels. 

Before operating at these levels, the performance test 

results must verify that, at the new levels, the facility 

comply with the emission limits in §§63.1178 and 63.1179 

of subpart DDD. 

9. The operations, maintenance, and monitoring plan must 

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 established 

operating levels or ranges for each process or control 

device. 

(b) A monitoring schedule. 

(c) Procedures for properly operating and maintaining control 

devices used to meet the standards in §§63.1178 and

63.1179 of this subpart. These procedures must include 

an inspection of each incinerator at least once per year. At 

a minimum, the facility must do the following as part of an 

incinerator inspection: 
30 

Federally Enforceable Provisos Regulations 

(1) Inspect all burners, pilot assemblies, and pilot sensing 

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 (such as 

baffles) to ensure structural integrity per the design 

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 lining if 

necessary. 

(7) Inspect incinerator shell for proper sealing, corrosion, 

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 practicable. 

(d) Procedures for keeping records to document compliance. 

(e) Corrective actions the facility will take if process 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 of the coke 

used in the cupola. 

ADEM Admin. Code R. 

335-3-1-.04 
31 

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 25th to September 24th November 23rd 

September 25th to March 24th May 24th 

ADEM Admin. Code 

335-3-16-.05(c)(3) 

3. A report shall be submitted semi-annually which contains the 

following: 

ADEM Admin. Code R. 

335-3-16-.05(c) 

(a) The periods when firebox temperate in the incinerator on 

the cupola was below 1320°F and the corrective action 

taken. 

(b) The periods when the pressure drops across the 

filterhouses were below the minimum pressure determined 

during the annual stack tests. 

4. All record shall be maintained for a minimum of 5 years. ADEM Admin. Code R. 

335-3-16-.05(c)2.(ii) 

5. This source shall comply with the notification requirements 

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 §63.10(b) of the 

general provisions in subpart A of this part, including 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 date 

and time of the alarm, when corrective actions were

initiated, the cause of the alarm, an explanation of 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 during 

the performance test, and all periods when the 

inspection identified incinerator components in need 

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 following 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 remaining 

three years of records may be retained off site. 

(d) Retain records on microfilm, on a computer, on computer 

disks, on magnetic tape disks, or on microfiche. 

(e) Report the required information on paper or on a labeled 

computer disk using commonly available and compatible 

computer software. 

7. The facility must prepare and submit reports to the

Administrator as required by this subpart and §63.10 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, that 

documents the process and control equipment operating 

parameters during the test period, the test methods and 

procedures, the analytical procedures, all calculations, 

and the results of the performance tests. 

(b) A startup, shutdown, and malfunction plan, as described 

in §63.6(e)(3) of the general provisions in subpart A of this 

part, that contains specific procedures for operating and 

maintaining the source during periods of startup, 

shutdown, and malfunction and a program of corrective 

action for malfunctioning process and control systems used 

to comply with the emission standards. In addition to the 

information required by §63.6(e)(3), the r plan must 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 process or 

control device malfunctions, including procedures for 

recording the actions taken to correct the malfunction 

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, including a 

report if an action taken during a startup, shutdown, or 

malfunction is inconsistent with the procedures in the 

plan as described in §63.6(e)(3) of the general provisions 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 measured 

emissions exceed the applicable standard or a monitored 

parameter varies from the level established during 

performance testing. The report must contain the 

information specified in §63.10(c) of the general provisions, 

as well as the relevant records required by §63.1192(b) of 

this subpart. 

(f) A semiannual report stating that no excess emissions 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 25th to September 24th November 23rd 

September 25th to March 24th May 24th 

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 NH3 N/A N/A 

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

199 Curing Oven Afterburner NH3 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/A 
35 

Provisos for Mineral Wool Process – Board Line 

Federally Enforceable Provisos Regulations 

Applicability

1. This source is 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. This unit is 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. This unit 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. 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 exceed 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 (Pipe 

Insulation Line) shall not exceed 117.0 (lb/hr) pounds per 

hour. 

ADEM Admin. Code R. 

335-3-14-.04(9) 

3. The facility must control emissions from each existing, 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 formaldehyde 

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 shutdown 

periods. 

ADEM Admin. Code 

335-3-14-.04(9) 

5. Maintain the free-formaldehyde content of each resin 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 binder used 

during the performance test. 

335-3-11-.06(55) 

[§63.1179(b)(1)] 

6. Maintain the operating temperature of each incinerator so that 

the average operating temperature for each three-hour block 

period never falls below the average temperature established 

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 (Subpart 

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 on 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 Procedures

1. If testing is required, particulate matter emissions 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 facility 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 this 

subpart while manufacturing the product that requires a 

binder formulation made with the resin containing the 

highest free-formaldehyde content specification range. 

Show compliance with the formaldehyde emission limits 

while the device for measuring incinerator operating 

temperature is installed, operational, and properly

calibrated. Establish the average operating temperature 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 highest 

free-formaldehyde content specification range, record the 

free-formaldehyde content specification range of the resin 

used, and the formulation of the binder used, including 

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 the 
37 

Federally Enforceable Provisos Regulations 

formaldehyde content. 

(e) Maintain the free-formaldehyde content of each resin lot 

and the formaldehyde content of each binder formulation 

at or below the specification ranges established during 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 incinerator so 

that the average operating temperature for each three-hour 

block period never falls below the average temperature 

established during the performance test. 

(h) Operate and maintain the incinerator as specified in your 

operations, maintenance, and monitoring plan required by 

§63.1187 of this subpart. 

(i) With prior approval from the Administrator, the facility 

may do short-term experimental production runs using 

resin where the free-formaldehyde content, or binder 

formulations where the formaldehyde content, is higher 

than the specification ranges of the resin and binder used 

during previous performance tests, or using experimental 

pollution prevention process modifications without first 

doing additional performance tests. Notification of intent to 

perform a short-term experimental production run must 

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 prevention 

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 compliance 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 §63.1189. 

335-3-11-.06(55) 

[§63.1188-1189] 

4. Using the results of the performance tests, the facility 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

1 2

× ×10

× × × ×

=

K P

C MW O K K

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-mole: 

CO = 28.01, Formaldehyde = 30.03. 

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

K1= Conversion factor, 1 kg/1,000 g (1 lb/453.6 g). 

K2= Conversion factor, 1,000 L/m3 (28.3 L/ft3 ). 

K3= 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 curing oven 

shall be installed, calibrated, maintained, and operated. 

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 monitored 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 following pollutants 

at intervals not to exceed one year following the date of initial 

compliance testing. All test reports must be submitted to the 

ADEM Admin. Code 

335-3-1-.04 
39 

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 incinerator: 

ADEM Admin. Code R. 

335-3-11-.06(55) 

[§63.1185] 

(a) During the performance test, the facility must establish 

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-hour 

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 onehour 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 record 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 paragraphs 

(a)(1) through (a)(4) of this section. 

7. The facility may change control device and process operating 

parameter levels established during performance tests 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 operating 
40 

Federally Enforceable Provisos Regulations 

parameter level. 

(b) Upon approval from the Administrator, you must conduct 

additional performance tests at the proposed new control 

device or process operating parameter levels. Before 

operating at these levels, the performance test results 

must verify that, at the new levels, you comply with the 

emission limits in §§63.1178 and 63.1179 of this subpart. 

8. The operations, maintenance, and monitoring plan must 

include the following: 

ADEM Admin. Code R. 

335-3-11-.06(55) 

[§63.1187(b)] 

(a) Process and control device parameters you will monitor to 

determine compliance, along with established operating 

levels or ranges for each process or control device. 

(b) A monitoring schedule. 

(c) Procedures for properly operating and maintaining control 

devices used to meet the standards in §§63.1178 and

63.1179 of this subpart. These procedures must include 

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 sensing 

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 (such as 

baffles) to ensure structural integrity per the design 

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 lining if 

necessary. 

(7) Inspect incinerator shell for proper sealing, corrosion, 

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 practicable. 

(d) Procedures for keeping records to document compliance. 

(e) Corrective actions you will take if process or control 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 25th to September 24th November 23rd 

September 25th to March 24th May 24th 

ADEM Admin. Code R. 

335-3-16-.05(c)3. 

2. A report shall be submitted semi-annually which contains 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 corrective 

action take; 

(b) The periods when the pressure drops across the 

filterhouses were below the minimum pressure determined 

during the annual stack tests; 

3. All record shall be maintained for a minimum of 5 years. ADEM Admin. Code R. 

335-3-16-.05(c)3. 

4. This source shall comply with the notification requirements 

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 §63.10(b) of 

the general provisions in subpart A of this part, including 

all notifications and reports. 

(b) Maintain records of the following information also: 

(1) All bag leak detection system alarms. Include the date 

and time of the alarm, when corrective actions were

initiated, the cause of the alarm, an explanation of 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 manufacture 

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 during 

the performance test, and all periods when the 

inspection identified incinerator components in need 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 following 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 remaining 

three years of records may be retained off site. 

(d) Retain records on microfilm, on a computer, on computer 

disks, on magnetic tape disks, or on microfiche. 

(e) Report the required information on paper or on a labeled 

computer disk using commonly available and compatible 

computer software. 

6. The facility must prepare and submit reports to the

Administrator as required by this subpart and §63.10 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 
43 

Federally Enforceable Provisos Regulations 

the general provisions in subpart A of this part, that 

documents the process and control equipment operating 

parameters during the test period, the test methods and 

procedures, the analytical procedures, all calculations, and 

the results of the performance tests. 

(b) A startup, shutdown, and malfunction plan, as described 

in §63.6(e)(3) of the general provisions in subpart A of this 

part, that contains specific procedures for operating and 

maintaining the source during periods of startup, 

shutdown, and malfunction and a program of corrective 

action for malfunctioning process and control systems 

used to comply with the emission standards. In addition 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 control 

device malfunctions, including procedures for 

recording the actions taken to correct the malfunction 

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, including a 

report if an action taken during a startup, shutdown, or 

malfunction is inconsistent with the procedures in the plan 

as described in §63.6(e)(3) of the general provisions 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 measured 

emissions exceed the applicable standard or a monitored 

parameter varies from the level established during 

performance testing. The report must contain the 

information specified in §63.10(c) of the general provisions, 

as well as the relevant records required by §63.1192(b) of 

this subpart. 
44 

Federally Enforceable Provisos Regulations 

(f) A semiannual report stating that no excess emissions 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 25th to September 24th November 23rd 

September 25th to March 24th May 24th 

ADEM Admin. Code R. 

335-3-11-.06(1) 

[§63.10(a)(5)] 
45 

Summary Page for Mineral Wool Process – Pipe Insulation 

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 NH3 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 requirements 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 Emissions”. 

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. 335-3-14-

.04. “Air Permits Authorizing Construction in Clean Air Areas 

[Prevention of Significant Deterioration]”. 

ADEM Admin. Code R. 

335-3-14-.04 

Emission Standards

1. Visible emissions (VE) these units shall not exceed 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 (Pipe Insulation 

Line) shall not exceed 117.0 (lb/hr) pounds per hour. 

ADEM Admin. Code R. 

335-3-14-.04(9) 

3. The baghouse shall not be bypassed during startup or for more 

than four (4) hours during shutdown periods. 

ADEM Admin. Code 

335-3-14-.04(9) 

Compliance and Performance Test Methods and Procedures

1. If testing is required, particulate matter emissions 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 monitored 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 conducted at 

intervals not to exceed one year following the date of initial 

compliance testing. All test reports must be submitted to the 

Department within 15 days of completion of testing.

ADEM Admin. Code 

335-3-1-.04 
47 

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 25th to September 24th November 23rd 

September 25th to March 24th May 24th 

ADEM Admin. Code R. 

335-3-16-.05(c)3. 

2. A report shall be submitted semi-annually which contains 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 determined 

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 Inspection 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