FORM A-1

PARENT COMPANY INFORMATION

I. Parent Company / Legal Corporate Owner Information

 1. Legal Parent Company / Legal Corporate Name Johns Manville

 2. Address 717 17th Street

 3. City Denver

 4. State Colorado

 5. Zip Code 80202

 6. County Denver

 7. Size of Company (approximate number of employees including 

all subsidiaries, branches, and related establishments owned):

6,491 (end of 2009)

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
FORM A-2

FACILITY INFORMATION

II. Facility Information

 Facility Name Johns Manville-Penbryn, NJ Facility

 Facility Address

 Street 437 N. Grove St

 City Berlin

 State New Jersey

 Zip Code 08009

 County Camden

 Facility Coordinates

 Latitude (decimal degrees, six decimal places) 39.757078

 Longitude (decimal degrees, six decimal places) 74.939037

 Specific location represented (e.g., front door of main 

building, centroid of property, etc.) Front Door

 Number of employees attached to the wool fiberglass 

manufacturing facility:

See CBI Submittal

 Design capacity of the plant (tons/yr) See CBI Submittal

 Type(s) of process(es) (rotary spin, flame attenuation) at 

this plant Rotary Spin

 Operation schedule

 hrs/day Currenty-0, 2008-24

 days/yr Currently-0, 2008-7

 Identify what state and local air pollution rules and 

regulations, including permit requirements, your plant is 

subject to. (Please provide copies of permit(s) and permit 

IDs)

N.J.A.C.; 7:27-6, 7:27-8, 7:27-16. See Attachment "A" for copies of 

permit limitations and application forms.

III. Technical Contact

 Name Mark Uscinowicz

 Technical Contact Title Manager of Process and Quality

 Telephone 356 768-7036

 Facsimile (Fax) 356 768-7061

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
 Email Mark.Uscinowicz@jm.com

IV. Other

 Is the facility a major source of HAP? No

 

 If No, did the facility take a limit of its potential HAP 

emissions to avoid classification as a major source: No, true minor

 Does the facility manufacture other products in 

addition to wool fiberglass? No

 If Yes, list the other products manufactured at the 

facility.

NA

 Are there any HAP emissions associated with any colocated facilities? List unit operations, e.g., boiler, and 

pollutant/emissions.

No

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
FORM B-1

PLANT OPERATIONS

I. Overview of Plant Operations

Number of process lines. Include lines that are currently

operational or that are temporarily shutdown. (Do not 

include lines permanently shutdown).

1

For each process line: Process Line 1 Process Line 2 Process Line 3

 Process line identification names or numbers Line 58

 Type of process line (e.g., rotary spin, flame attenuation) Rotary Spin

 Maximum annual production rate (tons/yr) See CBI Submittal

 Age of process equipment (yrs) 25

 Remaining economic life of process line (yrs) Indefinite (due to 

rebuild capabilities)

 List of products produced and most recent annual 

production (tons/yr; specify year) for each product See CBI Submittal

Please attach detailed schematics of each process line. See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
FORM B-2

PLANT OPERATIONS

II. Process - Raw materials Handling and Storage

 Molten glass preparation

 Raw materials and proportions by wt (%) See CBI Submittal

 Method(s) of conveying each raw material to furnace/pots Pneumatic Conveyance

 Binder and Additives

 List each raw material, including premixed materials, in the 

binder formulation and its proportion by wt (%) See CBI Submittal

 List steps in preparing binder, including storage 

temperature (°F) and holding time (hrs) See CBI Submittal

 Total yearly consumption of binder (gal/yr) See CBI Submittal

 Cost of binder ($/gal) for most recent year (specify year) See CBI Submittal

 Are binder storage and mixing tanks vented to 

outside/inside? Inside

 Method of treating vent air from storage and mix tanks None

 Emission control during liquid raw material transfer from 

vehicles to storage tanks. Resin has a filter

The binder for all plant products was converted to a non- Describe future source reduction plans and schedules to 

reformulate binders; List each constituent, proportions wt (%), 

cost ($/gal) for reformulation

HAP binder in 2002 that significantly reduces or 

eliminates HAP emissions from the manufacturing 

process.

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
FORM B-3

PLANT OPERATIONS

III. Process - Glass Melting Furnace (Electric Melters)

 For each Glass Melting Furnace: Electric Melters Furnace 2 Furnace 3

 Process unit identification name/number Module 1, 2 & 3 E17, 

E18 & E19

 Process line(s) served (identification name/number) Line 58

 Latitude (decimal degrees, six decimal places) 39.758930

 Longitude (decimal degrees, six decimal places) -74.439917

 Stack or vent height (units) 115 ft

 Stack or vent diameter (units) 38 in

 Manufacturer and model JM Proprietary

 Date of original installation 1985

 Estimate of remaining lifetime (yrs)

Indefinite (due to 

continued 

maintenance)

 Major rebuilds:

 What constitutes a major rebuild

JM is not familiar with 

the term "major 

rebuild." JM conducts 

periodic routine 

maintenace.

 Frequency of a major rebuild N/A

 Cost of typical major rebuild N/A

 Date of last major rebuild N/A

 Purpose of last major rebuild N/A

 Increase or decrease in emissions N/A

 Fuel type: electric, gas, or oil Electric

 Fuel consumption rate (KW/ton of glass or Btu/ton of 

glass) See CBI Submittal

 List HAPs that are in refractory material Chromium 

Compounds

 Design production rate (tons/day) See CBI Submittal

 Actual glass pull rate (tons/day) See CBI Submittal

 Vent gas flow rate (acfm @ °F)

397,452 acfm @ 

119OF

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
 Temperature (°F) of molten glass in furnace and 

forehearth (if applicable) See CBI Submittal

 Nature and frequency of routine/preventive maintenance 

procedures See CBI Submittal

 Describe process modification(s) since 1999 that reduce 

emissions None

 Describe future source reduction plans and schedules See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
FORM B-4

PLANT OPERATIONS

IV. Process - Forming -- Rotary Spin / Flame Attenuation

 For each Forming Operation -- Rotary Spin/Flame Attenuation Forming Operation 1 Forming Operation 2 Forming Operation 3

 Process unit identification name/number Module 1 E1 Module 2 E2 Module 3 E3

 Process line(s) served (identification name/number) Line 58 Line 58 Line 58

 Latitude (decimal degrees, six decimal places) 37.758703 37.758780 37.758861

 Longitude (decimal degrees, six decimal places) -74.939634 -74.939699 -74.9397764

 Stack or vent height (units) 68 in 68 in 68 in

 Stack or vent diameter (units) 69 ft 69 ft 69 ft

 Number of fiber forming devices (spinners) per line. See CBI Submittal See CBI Submittal See CBI Submittal

 Method of attenuating fiber (e.g., air, flame, or air and flame). 

Indicate type of burner used (if flame). Air Air Air

 Is there a forehearth between the furnace and the forming 

section? No No No

 Major rebuilds:

 What constitues a major rebuild

JM is not familiar with the 

term "major rebuild." JM 

conducts periodic routine 

maintenace.

JM is not familiar with the 

term "major rebuild." JM 

conducts periodic routine 

maintenace.

JM is not familiar with the 

term "major rebuild." JM 

conducts periodic routine 

maintenace.

 Frequency of a major rebuild N/A N/A N/A

 Cost of typical major rebuild N/A N/A N/A

 Date of last major rebuild N/A N/A N/A

 Purpose of last major rebuild N/A N/A N/A

 Increase or decrease in emissions N/A N/A N/A

 If modular, number of modules and plenums Each module listed 

separately

Each module listed 

separately

Each module listed 

separately

 Presence of water overspray and application rate (gpm) See CBI Submittal See CBI Submittal See CBI Submittal

 Binder applied and application rate (gpm) See CBI Submittal See CBI Submittal See CBI Submittal

 Other material applied and application rate (gpm) See CBI Submittal See CBI Submittal See CBI Submittal

 Temperature of glass fiber when binder is applied (°F) See CBI Submittal See CBI Submittal See CBI Submittal

 Temperature of binder when applied to fibers (°F) See CBI Submittal See CBI Submittal See CBI Submittal

 Method of evenly distributing fibers onto forming conveyor See CBI Submittal See CBI Submittal See CBI Submittal

 Formed mat thickness (in.) See CBI Submittal See CBI Submittal See CBI Submittal

 Forming air flow rate (acfm @ °F) 50,000 acfm @ 125o

F 50,000 acfm @ 125oF 50,000 acfm @ 125oF

 Percent of forming air recirculated and percent exhausted 100% Exhausted 100% Exhausted 100% Exhausted

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
 Nature and frequency of routine/preventive maintenance 

procedures See CBI Submittal See CBI Submittal See CBI Submittal

 Describe process modification(s) since 1999 that reduce 

emissions

The binder for all plant 

products was converted 

to a non-HAP binder in 

2002 that significantly

reduces or eliminates 

HAP emissions from the 

manufacturing process.

The binder for all plant 

products was converted 

to a non-HAP binder in 

2002 that significantly

reduces or eliminates 

HAP emissions from the 

manufacturing process.

The binder for all plant 

products was converted 

to a non-HAP binder in 

2002 that significantly

reduces or eliminates 

HAP emissions from the 

manufacturing process.

 Describe future source reduction plans and schedules See CBI Submittal See CBI Submittal See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
FORM B-5

PLANT OPERATIONS

V. Process - Curing 

 For each Curing Oven: Curing Oven 1 Curing Oven 2 Curing Oven 3

 Process unit identification name/number

Line 58 Curing Oven N. 

HEAF E4

Line 58 Curing Oven S. 

HEAF E4

 Process line(s) served (identification name/number) Line 58 Line 58

 Latitude (decimal degrees, six decimal places) 39.758361 39.758281

 Longitude (decimal degrees, six decimal places) -74.939400 -74.939325

 Stack or vent height (units) 36 in 36 in

 Stack or vent diameter (units) 72 ft 72 ft

 Method of curing Hot Air Recirculation Hot Air Recirculation

 Manufacturer and model

Originally installed by MidWest conveyor Co. Modified 

by K.C. Industrial 1974, 

modified and enlarged in 

1985

Originally installed by MidWest conveyor Co. Modified 

by K.C. Industrial 1974, 

modified and enlarged in 

1985

 Date of original installation 1974 1974

 Major rebuilds:

 What constitutes a major rebuild

JM is not familiar with the 

term "major rebuild." JM 

conducts periodic routine 

maintenace.

JM is not familiar with the 

term "major rebuild." JM 

conducts periodic routine 

maintenace.

 Frequency of a major rebuild N/A N/A

 Cost of typical major rebuild N/A N/A

 Date of last major rebuild N/A N/A

 Purpose of last major rebuild N/A N/A

 Increase or decrease in emissions N/A N/A

 Fuel type: electric, gas, or oil Natural Gas Natural Gas

 Fuel consumption rate (KW/hr or BTU/hr) See CBI Submittal See CBI Submittal

 Moisture content wt (%) of formed mat: 

 inlet See CBI Submittal See CBI Submittal

 outlet 0 0

 Air flow rate (acfm @ °F) from curing 39,000 @ 120o

 F 39,000 @ 120o F 

 Exhaust air temperature (°F) 240o

 F 240o F

 Residence time of product (mins) See CBI Submittal See CBI Submittal

 Binder content of cured product (LOI) 6% 6%

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
 Nature and frequency of routine/preventive 

maintenance procedures See CBI Submittal See CBI Submittal

 Describe process modification(s) since 1999 that 

reduce emissions

The binder for all plant 

products was converted to a 

non-HAP binder in 2002 that 

significantly reduces or 

eliminates HAP emissions 

from the manufacturing 

process.

The binder for all plant 

products was converted to a 

non-HAP binder in 2002 that 

significantly reduces or 

eliminates HAP emissions 

from the manufacturing 

process.

 Describe future source reduction plans and 

schedules See CBI Submittal See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
FORM B-6

PLANT OPERATIONS

VI. Process - Cooling

 For each Cooling Operation: Cooling Operation 1 Cooling Operation 2 Cooling Operation 3

 Process unit identification name/number Line 58 Cooling E5

 Process line(s) served (identification name/number) Line 58

 Latitude (decimal degrees, six decimal places) 39.758194

 Longitude (decimal degrees, six decimal places) -74.939261

 Stack or vent height (units) 72 ft

 Stack or vent diameter (units) 30 in.

 Cooling air flow rate (acfm @ °F) 14,500 @ 120o

 F

 Percentage of cooling air recirculated (if any) None

 Cooling air temperature (°F) Ambient

 Nature and frequency of routine/preventive 

maintenance procedures See CBI Submittal

 Describe process modification(s) since 1999 that 

reduce emissions

The binder for all plant 

products was converted to a 

formaldehyde free binder in 

2002. That significantly

reduces or eliminates HAP 

emissions from the 

manufacturing process.

 Describe future source reduction plans and schedules See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
FORM B-7

PLANT OPERATIONS

VII. Process - Use of Solvents

 Use of Solvents

 Volatile solvents used at your facility (where and how used)

By agreement this question was limited to HAP containing 

solvents. We interpret this question to apply to wool 

fiberglass lines, from melting through cooling. None

 List each solvent used and quantity (gal/yr) N/A

 Emission control device(s) used to control emissions from solvent 

usage/storage? N/A

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
FORM B-8

PROCESS OPERATIONS

VIII. Pollution Prevention

Please describe any work practices, pollution prevention techniques, 

and control strategies evaluated and/or implemented at each process 

unit at your facility (e.g., binder reformulation, alternative fuels usage, 

etc.) to reduce emissions of PM and HAPs you identified in Form E. 

You must specify the year in which the facility implemented the 

practice/technique and identify the emission reductions (if measured) 

from these practices/techniques.

JM objects to this question in that it is unbounded in time. 

We interpret this question, like similar questions in the 

ICR, to seek data since 1999. With that interpretation, JM 

responds that the binder was reformulated to a 

formaldehyde free resin in 2002.

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
FORM C-1

AIR POLLUTION CONTROL

I. Electrostatic Precipitator (ESP)

 For each ESP: ESP 1 ESP 2 ESP 3

 Process line(s) (identification name/number) There is no ESP at this 

facility.

 Equipment/process(es) controlled. Include emission point 

designations (e.g., E3, E4 from plot plan)

 Latitude (decimal degrees, six decimal places)

 Longitude (decimal degrees, six decimal places)

 Stack or vent height (units)

 Stack or vent diameter (units)

 Manufacturer and model

 Date of original installation

 Number of collection plates and configuration

 Gas flow rate to ESP (acfm @ °F)

 Inlet gas temperature (°F)

 Outlet gas temperature (°F)

 Inlet grain loading (gr/dscf)

 Outlet grain loading (gr/dscf)

 Average stack opacity (%)

 Pressure drop across ESP (in. H2O gauge)

 Plate area (ft2)

 Vendor guarantee on ESP efficency (attach copy)

 Method of plate cleaning and frequency

 Flow rate of plate washwater to ESP (gpm), if applicable

 Temperature of plate washwater to ESP (°F), if applicable

 Source of plate washwater used for cleaning, if applicable

 Concentration (mg/l) of dissolved and suspended solids in plate 

washwater, if applicable

 Conditioning agents used and amounts (in gpm or lbs/hr), if 

applicable

 Amount of wastewater generated (gpd), if applicable

 Amount of wastewater recycled (gpd), if applicable

 Amount of wastewater disposed of (gpd), if applicable

 Method of wastewater disposal, if applicalbe

 Quantity of solid waste collected (lbs/yr)

 Quantitiy of solid waste recycled (lbs/yr)

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
 Quantity of solid waste disposed of (lbs/yr)

 Method of solid waste disposal

 Nature and frequency of routine/preventive maintenance 

procedures

 Problems experienced with control device within the last five 

years; how were problems solved?

 Continuous monitoring method(s) used to monitor ESP 

performance, including parameters monitored

 Describe any plans to replace or upgrade ESP

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
FORM C-2

AIR POLLUTION CONTROL

II. Scrubber

 For each Scrubber: Scrubber 1 Scrubber 2 Scrubber 3

 Process line(s) (identification name/number)

There is no Scrubber at 

this facility.

 Equipment/process(es) controlled. Include emission point 

designations (e.g., E3, E4 from plot plan)

 Latitude (decimal degrees, six decimal places)

 Longitude (decimal degrees, six decimal places)

 Stack or vent height (units)

 Stack or vent diameter (units)

 Manufacturer and model

 Date of original installation

 Type (e.g., venturi, orifice)

 Gas flow rate to scrubber (acfm @ °F)

 Inlet gas temperature (°F)

 Outlet gas temperature (°F)

 Inlet grain loading (gr/dscf)

 Outlet grain loading (gr/dscf)

 Average stack opacity (%)

 Water flow rate to scrubber (gpm)

 Percent of scrubber water from recycled wastewater

 Source of scrubbing water and type of pretreatment. Substance(s) 

added as part of pretreatment and amount used (gpm or lbs/hr)

 HAP composition of wastewater (mg/L)

 Concentration (mg/L) of dissolved and suspended solids in 

scrubbing water

 Scrubbing water temperature (°F)

 Liquid/gas ratio (gal/103 acfm)

 Pressure drop across scrubber (in. H2O gauge)

 Amount of wastewater generated (gpd)

 Amount of wastewater recycled (gpd)

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
 Amount of wastewater disposed of (gpd)

 Method of wastewater disposal

 Quantity of solid waste collected (lbs/yr)

 Quantity of solid waste recycled (lbs/yr)

 Quantity of solid waste disposed of (lbs/yr)

 Method of solid waste disposal

 Vendor guarantee on scrubber efficiency (attach copy)

 Nature and frequency of preventive maintenance procedures

 Problems experienced with control device within the last five years; 

how were problems solved?

 Continuous monitoring method(s) used to monitor scrubber 

performance, including parameters monitored

 Plans to replace or upgrade scrubber

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
FORM C-3

AIR POLLUTION CONTROL

III. Mechanical Collector

 For each Mechanical Collector: Mechanical Collector 1 Mechanical Collector 2 Mechanical Collector 3

 Process line(s) (identification name/number)

There is no Mechanical 

Collector at this facility.

 Equipment/process(es) controlled. Include emission point 

designations (e.g., E3, E4 from plot plan)

 Latitude (decimal degrees, six decimal places)

 Longitude (decimal degrees, six decimal places)

 Stack or vent height (units)

 Stack or vent diameter (units)

 Manufacturer and model

 Date of original installation

 Type of mechanical collector 

 Gas flow rate to collector (acfm @ °F)

 Inlet gas temperature (°F)

 Outlet gas temperature (°F)

 Inlet grain loading (gr/dscf)

 Outlet grain loading (gr/dscf)

 Average stack opacity (%)

 Overall pressure drop (in. H2O gauge)

 Vendor guarantee on mechanical collector efficiency (attach 

copy)

 Quantity of solid waste collected (lbs/yr)

 Quantity of solid waste recycled (lbs/yr)

 Quantity of solid waste disposed of (lbs/yr)

 Method of solid waste disposal

 Nature and frequency of preventive maintenance procedures

 Problems experienced with control device within the last five 

years; how were problems solved?

 Continuous monitoring method(s) used to monitor performance, 

including parameters monitored

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
 Plans to replace or upgrade mechanical collector

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
FORM C-4

AIR POLLUTION CONTROL

IV. Fabric Filter 

 For each Fabric Filter: Fabric Filter 1 Fabric Filter 2 Fabric Filter 3

 Process line(s) (identification name/number) Line 58 Melter Dust Collector

 Equipment/process(es) controlled. Include emission 

point designations (e.g., E3, E4 from plot plan)

Controls dust/particulate from 

three glass melters E17-E19

 Latitude (decimal degrees, six decimal places) 39.758930

 Longitude (decimal degrees, six decimal places) -74.439917

 Stack or vent height (units) 115 ft

 Stack or vent diameter (units) 32 in

 Manufacturer and model Ecolaire (2) 625-8

 Date of original installation December 1984

 Number of compartments 4

 Number of bags per compartment 160

 Filter material and coatings applied Polypropylene needle felted 

with singed finish

 Fabric weight (oz/yd

2

) 16

 Filter surface area (ft2) 7500

 Gas flow rate to filter (acfm @ °F) 36,000 @ 125o

F

 Inlet gas temperature (°F) Ambient

 Outlet gas temperature (°F) Ambient

 Inlet grain loading (gr/dscf) Unknown

 Outlet grain loading (gr/dscf) 0.0016

 Average stack opacity (%) 0

 Overall pressure drop (in. H2O gauge) 3.5

 Method and frequency of bag cleaning

1st hour compartment No. 1 

shakes for 8 minutes, 2nd hour 

compartment No. 2 shakes for 

8 minute, etc.

 Vendor guarantee on fabric filter efficiency (attach 

copy)

Written guarantee is not 

available, about 99%

 Quantity of solid waste collected (lbs/yr) 949,870

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
 Quantity of solid waste recycled (lbs/yr) Dust 100% recycled (930,750 

lb/yr)

 Quantity of solid waste disposed of (lbs/yr) 19,120 lb/year waste filter bags

 Method of solid waste disposal Landfill

 Nature and frequency of preventive maintenance 

procedures

Every 3 months following dust 

collector Preventative 

Maintenance in Attachment C

 Problems experienced with control device within the 

last five years; how were problems solved?

Nothing specific, general wear 

and maintenance items

 Continuous monitoring method(s) used to monitor 

performance, including parameters monitored None

 Plans to replace or upgrade fabric filter See CBI submittal

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
FORM C-5

AIR POLLUTION CONTROL

V. Thermal Incinerator

 For each Thermal Incinerator: Thermal Incinerator 1 Thermal Incinerator 2 Thermal Incinerator 3

 Process line(s) (identification name/number)

There is no Thermal 

Incinerator at this facility.

 Equipment/process(es) controlled. Include emission 

point designations (e.g., E3, E4 from plot plan)

 Latitude (decimal degrees, six decimal places)

 Longitude (decimal degrees, six decimal places)

 Stack or vent height (units)

 Stack or vent diameter (units)

 Manufacturer and model

 Date of original installation

 Fuel type: gas or oil

 Fuel consumption rate (BTU/hr)

 Inlet gas flow rate (acfm @ °F)

 Inlet gas temperature (°F)

 Combustion chamber gas temperature (°F)

 Outlet gas temperature (°F)

 Inlet grain loading (gr/dscf)

 Outlet grain loading (gr/dscf)

 Average stack opacity (%)

 Excess air (%)

 Residence time (sec) at temperature (°F)

 Percent heat recovery

 Vendor guarantee on incinerator efficiency (attach 

copy)

 Nature and frequency of preventive maintenance 

procedures

 Problems experienced with control device within the 

last five years; how were problems solved?

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
 Continuous monitoring method(s) used to monitor 

incinerator performance, including parameters monitored

 Plans to replace or upgrade thermal incinerator

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
FORM C-6

AIR POLLUTION CONTROL

VI. High Velocity Air Filter (HVAF) 

 For each HVAF: HEAF 1 HEAF 2 HVAF 3

Line 58 North HEAF Line 58 South HEAF

 Equipment/process(es) controlled. Include emission 

point designations (e.g., E3, E4 from plot plan) Line 58 Curing Oven E4 Line 58 Curing Oven E4

 Latitude (decimal degrees, six decimal places) 39.758361 39.758281

 Longitude (decimal degrees, six decimal places) -74.939400 -74.939325

 Stack or vent height (units) 72 ft 72 ft

 Stack or vent diameter (units) 36 inches 36 inches

 Manufacturer and model Johns Manville Design and 

fabrication

Johns Manville Design and 

fabrication

 Date of original installation 1973 1988

 Inlet gas flow rate (acfm @ °F) 28,000 @ 125o F 35,000 @ 125o F

 Inlet gas temperature (°F) 130 130

 Outlet gas temperature (°F) 120 120

 Inlet grain loading (gr/dscf) Unknown Unknown

 Outlet grain loading (gr/dscf) 0.004 g/dscf 0.004 g/dscf

 Average stack opacity (%) Less than 10 % Less than 10 %

 Water spray pressure (sdig), if applicable 28 psi 28 psi

 Water spray rate (gpm), if applicable 56 gpm 56 gpm

 Filter face velocity (acfm/ft2) Not Available Not Available

 Maximum pressure drop across mat (in. H2O gauge) 1.75 1.75

 Vendor guarantee on HVAF efficiency (attach copy) Not Available Not Available

 Method and frequency of filter mad advancement

Automatic advancement 

based upon time average: 

every 13 minutes

Automatic advancement 

based upon time average: 

every 13 minutes

 Amount of wastewater generated (gpd) 4,320 4,320

 Amount of wastewater recycled (gpd) 100% (4,320 gpd) 100% (4,320 gpd)

 Amount of wastewater disposed of (gpd) 0 0

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
 Method of wastewater disposal Not Applicable Not Applicable

 Quantity of solid waste collected (lbs/yr) 26690 for both HEAFs 26690 for both HEAFs

 Quantity of solid waste recycled (lbs/yr) 0 0

 Quantity of solid waste disposed of (lbs/yr) 26690 for both HEAFs 26690 for both HEAFs

 Method of solid waste disposal Landfill

 Nature and frequency of preventive maintenance 

procedures

Every two weeks preventative 

maintenance electrical and 

mechanical 

Every two weeks preventative 

maintenance electrical and 

mechanical

 Problems experienced with control device within the 

last five years; how were problems solved?

Problems are related to 

cogging of the chain and drum 

due to sticky build-up. This 

problem has not been solved, 

but our means of addressing it 

is to have more frequent 

cleaning.

Problems are related to 

cogging of the chain and drum 

due to sticky build-up. This 

problem has not been solved, 

but our means of addressing it 

is to have more frequent 

cleaning.

 Continuous monitoring method(s) used to monitor 

HVAF performance, including parameters monitored Pressure drop across the unit. Pressure drop across the unit. 

 Plans to replace or upgrade HVAF See CBI submittal See CBI submittal

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
FORM C-7

AIR POLLUTION CONTROL

VII. Mist Eliminator

 For each Mist Eliminator: Mist Eliminator 1 Mist Eliminator 2 Mist Eliminator 3

 Process line(s) (identification name/number)

There is no Mist Eliminator 

at this facility.

 Equipment/process(es) controlled. Include emission point 

designations (e.g., E3, E4 plot plan)

 Latitude (decimal degrees, six decimal places)

 Longitude (decimal degrees, six decimal places)

 Stack or vent height (units)

 Stack or vent diameter (units)

 Manufacturer and model

 Date of original installation

 Type of mist eliminator

 Gas flow rate to mist eliminator (acfm @ °F)

 Inlet gas temperature (°F)

 Outlet gas temperature (°F)

 Inlet grain loading (gr/dscf)

 Outlet grain loading (gr/dscf)

 Average stack opacity (%)

 Velocity in mist eliminator (ft/sec)

 Pressure drop (in. H2O gauge)

 For chevron blade mist eliminators:

 Spacing between blades (in.)

 Washing frequency of blades

 For mesh pad mist eliminators:

 Number of pads or elements

 Thickness of pad (in.) or element dimensions

 Density of pad, (lb/ft3)

 Washing frequency of pad

 Vendor guarantee on mist eliminator efficiency (attach copy)

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
 Amount of wastewater generated (gpd)

 Amount of wastewater recycled (gpd)

 Amount of wastewater disposed of (gpd)

 Method of wastewater disposal

 Quantity of solid waste collected (lbs/yr)

 Quantity of solid waste recycled (lbs/yr)

 Quantity of solid waste disposed of (lbs/yr)

 Method of solid waste disposal

 Nature and frequency of preventive maintenance procedures

 Problems experienced with control device within the last five 

years; how were problems solved?

 Continuous monitoring method(s) used to monitor mist eliminator 

performance, including parameters monitored

 Plans to replace or upgrade mist eliminator 

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
FORM C-8

AIR POLLUTION CONTROL

VIII. Ventilation System N/A

 For each Ventilation System: Ventilation System 1 Ventilation System 2 Ventilation System 3

 Process line(s) (identification name/number)

 Equipment/process(es) controlled. Include emission point 

designations (e.g., E3, E4 from plot plan)

 Latitude (decimal degrees, six decimal places)

 Longitude (decimal degrees, six decimal places)

 Stack or vent height (units)

 Stack or vent diameter (units)

 For general or building ventilation:

 Ventilation system used

 Airflow control system used

 Number of air changes per hour

 For unit or local ventilation:

 Enclosure or hood design used

 Volume of enclosure or hood

 Capture velocity (ft/sec)

 Distance between hood and emission source (ft)

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
FORM C-9

AIR POLLUTION CONTROL

IX. Other 

 For each Other Air Pollution Control Device (APCD): Other APCD 1 Other APCD 2 Other APCD 3

 Process line(s) (identification name/number) Line 58

 Equipment/process(es) controlled. Include emission point 

designations (e.g., E3, E4 from plot plan)

No other air pollution control 

devices at this facility.

 Latitude (decimal degrees, six decimal places)

 Longitude (decimal degrees, six decimal places)

 Stack or vent height (units)

 Stack or vent diameter (units)

 Description

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
FORM D

PROCESS LINE STARTUP AND SHUTDOWN

1. For each startup and shutdown (SS) that occurred during the last 

five years, please provide the following information requested in A. 

through J. 

 A. Using the definitions provided above, indicate whether the 

event was a startup or shutdown; No excess emission events during periods of startup and shutdown.

 B. A description of the event, including identification of the 

emissions source or sources associated with the startup or 

shutdown;

N/A

 C. Whether any permit condition was exceeded and, if so, what 

permit condition was exceeded; N/A

 D. Whether the event was covered by any contingency plan for 

controlling emissions during startup and shutdown events and, if so, 

whether the plan was followed; if the plan was not followed, why not;

N/A

 E. The duration of the event; N/A

 F. The actions taken to minimize emissions during the event, 

including the use of any backup control systems; N/A

 G. Estimates or measurements, if any, of emissions during the 

event; if you did not have the ability to quantify emissions during the 

event, please explain why;

N/A

 H. Whether the emission profile of each unit was different during 

startup and shutdown than during normal operating conditions and, if 

so, how emissions were different and why; please provide any

supporting information;

N/A

 I. All performance test data collected during each period of SS; 

the test method used for each event; when the testing was 

conducted and why; the test conditions at the time of testing; and 

whether the tests were associated with a routine startup or shutdown; 

and

No data available

 J. All monitoring data, including control system parameter 

monitoring, collected during each period of SS. All required Title V monitoring data would be collected.

Startup: the setting in operation of an affected source or portion of an affected source for any purpose.

Shutdown: the cessation of operation of an affected source or portion of an affected source for any purpose.

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
If this information is contained in periodic and immediate SS reports 

(either stand-alone or contained within the periodic excess emissions 

report) submitted to your permitting authority, you may submit copies 

of those reports instead.

2. Are there any types of startup or shutdown events that you have 

been able to eliminate? If so, please describe the type of event and 

explain how these events were eliminated.

N/A

3. Please submit a copy of your SS plan if you are required to 

develop one. No plan required

4. Please provide all performance test data collected during periods 

of SS over the last 5 years. Indicate the test method used for each 

event.

No data available

5. Please provide all monitoring data, including control system 

parameter monitoring, collected during periods of SS over the last 5 

years. 

N/A

6. Optional: Do you wish to recommend a standard that would apply

during startup or shutdown? If so, please describe the event to 

which the standard would apply; the recommended standard (this 

could be an emission limitation, work practice, or operational 

standard) that would apply during the period; the basis for the 

recommended standard; why and how the standard would minimize 

emissions during the event; and how would compliance be 

determined and/or monitored. 

No

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
FORM E

PRESENCE OF AIR POLLUTANTS IN EMISSION POINTSa

Please provide any existing emissions information and data 

covering hazardous air pollutants (HAP) and particulate matter 

(PM) for each listed process. Identify the appropriate box for 

which you are providing specific process information and/or 

pollutant emissions data.

Melting Furnace Forming Curing Cooling

Particulate Matter (PM, PM 2.5, PM Condensable) 

Chromium Compounds and Hexavalent Chromium (including 

any Cr speciation data)

Other metal HAP (As, Be, Cd, Co, Hg, Mn, Ni, Pb, Sb, Se)

Hydrogen Fluoride (HF)

Hydrogen Chloride (HCl)

The existing data requested here has been provided to EPA by the industry’s trade 

association, the North American Insulation Manufacturers Association (“NAIMA”). The 

existing data provided by NAIMA was set forth in NAIMA’s May 5, 2010 letter to EPA. 

The representative existing emissions data provided from fiber glass companies included 

test results for the following pollutants: formaldehyde, methanol, phenol, particulate 

matter, hydrogen fluoride, metals (antimony, arsenic, beryllium, cadmium, chromium, 

cobalt, lead, manganese, nickel, and selenium), mercury, and hexavalent chromium. 

The representative existing emissions data provided from mineral wool companies 

included test results for the following pollutants: formaldehyde, methanol, phenol, 

particulate matter, carbon monoxide, carbonyl sulfide, hydrogen fluoride, metals 

(antimony, arsenic, beryllium, cadmium, chromium, cobalt, lead, manganese, nickel, and 

selenium), mercury, and hexavalent chromium. The scope of the existing data provided 

was the result of consensus reached by EPA, NAIMA, and industry representatives. In 

addition to the existing 

data submitted to EPA, extensive new emissions data is being collected from 

virtually all companies through the “BTEC, Inc. Quality Assurance Project Plan for 

the Mineral Wool and Wool Fiberglass Emissions Test Program.” This Test Program will 

collect and submit to EPA, through EPA’s Electronic Reporting Tool, 

representative emissions data for the following pollutants: formaldehyde, methanol, 

phenol, particulate matter, carbon monoxide, carbonyl sulfide, hydrogen fluoride, 

metals (antimony, arsenic, beryllium, cadmium, chromium, cobalt, lead, manganese, 

nickel, and selenium), mercury, and hexavalent chromium.

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
Formaldehyde

Phenol

Methanol

Other organic HAP

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
FORM F-1 

COST

I. Process Unit (e.g., cupola, curing oven, etc.):

 For each Process Unit: Process Unit 1 Process Unit 2 Process Unit 3

 Process Unit ID All Units

 Process Line ID Line 58

II. Capital Costs

 Base year

JM objects to this request 

in its entirety because it 

seeks information that is 

not relevant to the EPA 

Administrator’s review 

obligations pursuant to 

Clean Air Act Section 

112(d)(6) and 112(f)(2).

 Total capital cost, including costs for individual pieces, if available. See Above 

III. Annual Operating Costs

 Base year (most recent fiscal year) See Above 

 Total annual operating costs See Above 

 Maintenance materials and replacement parts (specify costs by item)

 See Above 

 Raw materials costs See Above 

 Labor

 ($/yr) for each labor class See Above 

 (hr/hr) for each labor class See Above 

 Utilities (breakdown for each utility) See Above 

 Waste treatment and/or disposal See Above 

 Costs associated with any work practices and pollution prevention 

techniques that are employed at your facility See Above 

 Savings associated with heat recovery and wastewater and/or solid waste 

returned to process from APCD (or sold to another user) See Above 

 Indirect costs See Above 

 Other (specify) See Above 

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
Please provide the annual report to shareholders or equivalent for the most 

recent fiscal year. If reports are not available, provide annual sales and 

profits (or profit margin) for the most recent fiscal year. If company is 

publicly owned, please provide a web link to this information.

 See Above 

Identify the market range (regional, national, international) of your products. National 

Can your product(s) be substituted by another product(s)? If so, please list 

your product(s) and substituted product(s).

Wool fiberglass is used 

as insulation, as are 

cellulose (scrap 

newspaper) treated to 

resist fires, spray foam, 

foam boards, cotton 

treated to resist fires, and 

sheep wool treated to 

resist fires. Wool 

fiberglass insulation is 

preferred over these 

alternative insulation 

materials because it is 

easily, economically, and 

safety installed in various 

building settings, has 

superior fire performance 

capabilities, and a 70-

year history of proven 

performance and 

durability.

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
FORM F-2

COST

I. Air Pollution Control Device (APCD) See form F-1

 For each APCD: APCD 1

 APCD ID

 Process Unit ID

II. Capital Costs

 Base year 

JM objects to this 

request in its entirety

because it seeks 

information that is not 

relevant to the EPA 

Administrator’s review 

obligations pursuant 

to Clean Air Act 

Section 112(d)(6) and 

112(f)(2).

 APCD equipment purchase cost and what was included See above

 List the cost for each piece of auxiliary equipment for each APCD 

not included above See above

 Installation cost See above

 Land purchase cost See above

 Total capital cost See above

 Method of financining APCD See above

 Retrofit installation See above

 Field erected or modular See above

III. Annual Operating Costs

 Base year (most recent fiscal year) See above

 Maintenance materials and replacement parts (specify costs by

item)

See above

 Raw materials costs See above

 Labor

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls
 ($/yr) for each labor class See above

 (hr/hr) for each labor class See above

 Utilites (breackdown for each utility) See above

 Waste treatment and/or disposal See above

 Indirect costs See above

 Other (specify) See above

 Total annual operating cost (most recent fiscal year) See above

Attach annual report to shareholders or equivalent for the most 

recent fiscal year. Alternatively, if company is publicly owned, you 

can provide your company's web link to this information.

See above

EPA-HQ-OAR-2010-1042-DRAFT-0006.xls