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-0008.xls
FORM A-2

FACILITY INFORMATION

II. Facility Information

 Facility Name Johns Manville-Cleburne Plant

 Facility Address

 Street 200 West Industrial Boulevard

 City Cleburne

 State Texas

 Zip Code 76031

 County Johnson

 Facility Coordinates

 Latitude (decimal degrees, six decimal places) N32.38691

 Longitude (decimal degrees, six decimal places) W97.39483

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

of property, etc.) Front Door - Center Curb Line

 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 and Flame Attenuation

 Operation schedule

 hrs/day 24

 days/yr 365

 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)

Federal Title V Permit #01677

TCEQ Title V Permit #946A

PSDTX #1025M1 (See Attachment A)

III. Technical Contact

 Name Ricardo A. Santos

 Technical Contact Title Environmental Specialist

 Telephone 817-556-6659

 Facsimile (Fax) 817-556-7559

 Email santosr@jm.com

IV. Other

 Is the facility a major source of HAP? Yes

 

EPA-HQ-OAR-2010-1042-DRAFT-0008.xls
 If No, did the facility take a limit of its potential HAP emissions to avoid 

classification as a major source: Not Applicable

 Does the facility manufacture other products in addition to wool 

fiberglass? Yes

 If Yes, list the other products manufactured at the facility. Chopped Fibers and Reinforcements

 Are there any HAP emissions associated with any co-located facilities? 

List unit operations, e.g., boiler, and pollutant/emissions.

We interpret this to seek information on sources of HAPs other than 

wool fiber glass at the facility rather than co-located facilities. Yes. A 

solvent is used to clean the ink jet printer cartridges. Ink jet printers 

are used for print information on the product. This solvent is used at 

L91 and two mat coating process lines (L90 and L97). Methyl Alcohol 

compose about 5% of product. Gallons per year of this solvent used: 

35.17 gallons.1901 forming MeOH: Fug. Emissions 17,088 lbs/Yr (8.54 

TPY), HCHO emissions from binder tanks, combustion, and 

maintenance: Fug emissions 2,661 lbs/Yr (1.33 TPY).

EPA-HQ-OAR-2010-1042-DRAFT-0008.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).

3

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

 Process line identification names or numbers Line 91 Line 92 Line 93

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

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

 Age of process equipment (yrs) 20 46 45

 Remaining economic life of process line (yrs)

Indefinite (due to 

rebuild capabilities)

Indefinite (due to 

rebuild capabilities)

Indefinite (due to 

rebuild capabilities)

 List of products produced and most recent annual 

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

See CBI submittal See CBI submittal See CBI submittal

Please attach detailed schematics of each process line. See Attachment B See Attachment B See Attachment B

EPA-HQ-OAR-2010-1042-DRAFT-0008.xls
FORM B-2

PLANT OPERATIONS

II. Process - Raw materials Handling and Storage Process Line 1 - Line 91 Process Line 2 - Line 92 Process Line 3 - Line 93

 Molten glass preparation

 Raw materials and proportions by wt (%)

See CBI submittal Glass Marbles Glass Marbles

 Method(s) of conveying each raw material to 

furnace/pots Mechanical conveyance and gravity feed Bucket hopper and gravity Bucket hopper and gravity

 Binder and Additives

 List each raw material, including premixed materials, 

in the binder formulation and its proportion by wt (%) See CBI submittal See CBI submittal See CBI submittal

List steps in preparing binder, including storage 

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

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

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

year) See CBI submittal See CBI submittal See CBI submittal

Are binder storage and mixing tanks vented to 

outside/inside? Inside Inside Inside

 Method of treating vent air from storage and mix 

tanks No Treatment No Treatment No Treatment

Emission control during liquid raw material transfer from 

vehicles to storage tanks.

There are no emission controls on anything 

except the aqua ammonia transfer. When 

ammonia is unloaded, the holding tank is 

vented back into the truck.

There are no emission controls on anything 

except the aqua ammonia transfer. When 

ammonia is unloaded, the holding tank is 

vented back into the truck.

There are no emission controls on anything 

except the aqua ammonia transfer. When 

ammonia is unloaded, the holding tank is 

vented back into the truck.

Describe future source reduction plans and schedules to 

reformulate binders; List each constituent, proportions wt 

(%), cost ($/gal) for reformulation

See CBI submittal See CBI submittal See CBI submittal

EPA-HQ-OAR-2010-1042-DRAFT-0008.xls
FORM B-3

PLANT OPERATIONS

III. Process - Glass Melting Furnace

 For each Glass Melting Furnace: Line 91- Melters 1902 Furnace 3

 Process unit identification name/number L 91 F1902

 Process line(s) served (identification name/number) Unit 94, Unit 97 None

 Latitude (decimal degrees, six decimal places) N32.38827 N32.387693

 Longitude (decimal degrees, six decimal places) W97.39715 W97.393087

 Stack or vent height (units) 43 feet 78 feet

 Stack or vent diameter (units) 51 7/8" 65"

 Manufacturer and model JM Proprietary JM Proprietary

 Date of original installation 1990 1974

 Estimate of remaining lifetime (yrs)

Indefinite (due to continued 

maintenance)

Indefinite (due to continued 

maintenance)

 Major rebuilds:

 What constitues a major rebuild See CBI Submittal See CBI Submittal

 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 Electric Gas

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

glass) See CBI Submittal See CBI Submittal

 List HAPs that are in refractory material Chromium Compounds Chromium Compounds

 Design production rate (tons/day) See CBI Submittal See CBI Submittal

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

 Vent gas flow rate (acfm @ °F) 40,318 @ 145 °F 33,296 @ 322 °F

 Temperature (°F) of molten glass in furnace and 

forehearth (if applicable) See CBI Submittal See CBI Submittal

 Nature and frequency of routine/preventive 

maintenance procedures CBI See CBI Submittal See CBI Submittal

 Describe process modification(s) since 1999 that 

reduce emissions None None

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

EPA-HQ-OAR-2010-1042-DRAFT-0008.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 Line 91 Line 92 Line 93

 Process line(s) served (identification name/number) None None None

 Latitude (decimal degrees, six decimal places)

Module 1: N32.38801

Module 2: N32.38801

Module 3: N32.38802

Module 4: N32.38802

N32.38754 N32.3876

 Longitude (decimal degrees, six decimal places)

Module 1: W97.39708

Module 2: W97.39712

Module 3: W97.39713

Module 4: W97.39716

W97.39465 W97.39462

 Stack or vent height (units)

Refer to C-2 for stack 

information

EPN 1 53.5 ft

EPN 2 53.5 ft

EPN 4 53.708 ft

EPN 5 53.729 ft

 Stack or vent diameter (units)

Refer to C-2 for stack 

information

EPN 1 63.625x63.5 in

EPN 2 63.5x63.5625 in

EPN 4 63.5x64 in

EPN 5 63.5x64 in

 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 flame attenuation, gas burner

flame attenuation, gas 

burner

 Is there a forehearth between the furnace and the forming 

section? Yes 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 4 Non modular Non modular

 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 converyor 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)

Module 1: 21,582 @ 102 °F

Module 2: 22,687 @ 103 °F

Module 3: 22,085 @ 99 °F

Module 4: 23,496 @ 102 °F

2 fans @ 65000 CFM 

@160F

2 fans @ 65000 CFM 

@160F

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

 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

Reducing HAPs in binder 

formulations

Reducing HAPs in binder 

formulations

Reducing HAPs in binder 

formulations

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

EPA-HQ-OAR-2010-1042-DRAFT-0008.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 91 Curing Oven Line 92 Curing Oven Line 93 Curing Oven

 Process line(s) served (identification name/number) Line 91 Line 92 Line 93

 Latitude (decimal degrees, six decimal places) N32.38791 N32.38757 N32.38763

 Longitude (decimal degrees, six decimal places) W97.39664 W97.39479 W97.39474

 Stack or vent height (units)

Refer to C-2 (EPN 20) for 

stack info 

Refer to C-6 (EPN 3) for 

stack info 

Refer to C-6 (EPN 3) for 

stack info 

 Stack or vent diameter (units)

Refer to C-2 (EPN 20) for 

stack info 

Refer to C-6 (EPN 3) for 

stack info 

Refer to C-6 (EPN 3) for 

stack info 

 Method of curing Gas Oven Gas Oven Gas Oven

 Manufacturer and model

Continental Steel & 

Conveyors The R.C.MAHON Company The R.C.MAHON Company

 Date of original installation 1990 1964 1964

 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 NA NA NA

 Cost of typical major rebuild NA NA NA

 Date of last major rebuild NA NA NA

 Purpose of last major rebuild NA NA NA

 Increase or decrease in emissions NA NA NA

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

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

 Moisture content wt (%) of formed mat: 

 inlet See CBI Submittal See CBI Submittal See CBI Submittal

 outlet 0 0 0

 Air flow rate (acfm @ °F) from curing 52,452 24,183.50 24,183.50

 Exhaust air temperature (°F) Up to 450 degrees Up to 500 degress Up to 500 degress

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

 Binder content of cured product (LOI) 5% to 18% 5% to 16% 5% to 16%

 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

Reducing HAPs in binder 

formulations

Reducing HAPs in binder 

formulations

Reducing HAPs in binder 

formulations

 Describe future source reduction plans and 

schedules See CBI Submittal See CBI Submittal See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0008.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 91 Cooling Line 92 Cooling Line 93 Cooling

 Process line(s) served (identification name/number) Line 91 Line 92 Line 93

 Latitude (decimal degrees, six decimal places) N32.38791 N32.3875 N32.38763

 Longitude (decimal degrees, six decimal places) W97.3965 W97.395 W97.395

 Stack or vent height (units) Routed to curing control N/A N/A

 Stack or vent diameter (units) N/A N/A N/A

 Cooling air flow rate (acfm @ °F) N/A N/A N/A

 Percentage of cooling air recirculated (if any) None None None

 Cooling air temperature (°F) Ambient Ambient Ambient

 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

Reducing HAPs in binder 

formulations

Reducing HAPs in binder 

formulations

Reducing HAPs in binder 

formulations

 Describe future source reduction plans and 

schedules See CBI submittal See CBI submittal See CBI submittal

EPA-HQ-OAR-2010-1042-DRAFT-0008.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-0008.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. See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0008.xls
FORM C-1

AIR POLLUTION CONTROL

I. Electrostatic Precipitator (ESP)

 For each ESP: ESP 1

 Process line(s) (identification name/number) N/A

 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)

 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-0008.xls
FORM C-2

AIR POLLUTION CONTROL

II. Scrubber

 For each Scrubber: Scrubber 1 Scrubber 2 Scrubber 3 Scrubber 4 Oven Scrubber

 Process line(s) (identification name/number) Collection Scrubber 1 Collection Scrubber 2 Collection Scrubber 3 Collection Scrubber 4 Oven Scrubber

 Equipment/process(es) controlled. Include emission point 

designations (e.g., E3, E4 from plot plan) Line 91 - EPN 16 Line 91 - EPN 17 Line 91 - EPN 18 Line 91 - EPN 19 Line 91 - EPN 20

 Latitude (decimal degrees, six decimal places) N32.38796 N32.38795 N32.38796 N32.38794 N32.38785

 Longitude (decimal degrees, six decimal places) W97.39723 W97.39716 W97.39703 W97.39706 W97.39664

 Stack or vent height (units) 125 ft 125 ft 125 ft 125 ft 81.17 ft

 Stack or vent diameter (units) 59.0625 in 60 in 60.5 in 60.125 in 60 in

 Manufacturer and model AiPol Inc. Cyclonic C-V AiPol Inc. Cyclonic C-V AiPol Inc. Cyclonic C-V AiPol Inc. Cyclonic C-V AiPol Inc. Cyclonic C-V

 Date of original installation 1990 1990 1990 1990 1990

 Type (e.g., venturi, orifice) Venturi Venturi Venturi Venturi Venturi

 Gas flow rate to scrubber (acfm @ °F) 38,806 38,279 34,455 28,913 52,452

 Inlet gas temperature (°F) Not Available Not Available Not Available Not Available Not Available

 Outlet gas temperature (°F) 100 101 96 99 357

 Inlet grain loading (gr/dscf) Not Available Not Available Not Available Not Available Not Available

 Outlet grain loading (gr/dscf) 0.0083 0.0062 0.0075 0.0062 0.0059

 Average stack opacity (%) < 10% < 10% < 10% < 10% < 10%

 Water flow rate to scrubber (gpm) 600 600 600 600 630 max

 Percent of scrubber water from recycled wastewater 100% 100% 100% 100% 100%

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

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

City Water - Defoamer - 

1/2 gal as needed

City Water - Defoamer - 

1/2 gal as needed

City Water - Defoamer - 

1/2 gal as needed

City Water - Defoamer - 

1/2 gal as needed

City Water - Defoamer - 

1/2 gal as needed

 HAP composition of wastewater (mg/L) None Detected None Detected None Detected None Detected None Detected

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

scrubbing water N/A N/A N/A N/A N/A

 Scrubbing water temperature (°F) N/A N/A N/A N/A N/A

 Liquid/gas ratio (gal/103 acfm) N/A N/A N/A N/A N/A

 Pressure drop across scrubber (in. H2O gauge) 14 14 14 14 29 max

 Amount of wastewater generated (gpd) None None None None None

 Amount of wastewater recycled (gpd) None None None None None

 Amount of wastewater disposed of (gpd) None None None None None

 Method of wastewater disposal Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable

 Quantity of solid waste collected (lbs/yr) 203,087 203,087 203,087 203,087 203,087

 Quantity of solid waste recycled (lbs/yr) None None None None None

 Quantity of solid waste disposed of (lbs/yr) 203,087 203,087 203,087 203,087 203,087

 Method of solid waste disposal TCEQ Class 1 Landfill TCEQ Class 1 Landfill TCEQ Class 1 Landfill TCEQ Class 1 Landfill TCEQ Class 1 Landfill

 Vendor guarantee on scrubber efficiency (attach copy) None None None None None

 Nature and frequency of preventive maintenance procedures

Monthly - Inspect and 

repair 

Monthly - Inspect and 

repair 

Monthly - Inspect and 

repair 

Monthly - Inspect and 

repair 

Monthly - Inspect and 

repair 

 Problems experienced with control device within the last five years; 

how were problems solved? None None None None None

 Continuous monitoring method(s) used to monitor scrubber 

performance, including parameters monitored

Pressure Drop and Water 

Flow Rate

Pressure Drop and Water 

Flow Rate

Pressure Drop and Water 

Flow Rate

Pressure Drop and Water 

Flow Rate

Pressure Drop and Water 

Flow Rate

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

EPA-HQ-OAR-2010-1042-DRAFT-0008.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) N/A

 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

 Plans to replace or upgrade mechanical collector

EPA-HQ-OAR-2010-1042-DRAFT-0008.xls
FORM C-4

AIR POLLUTION CONTROL

IV. Fabric Filter 

 For each Fabric Filter: Fabric Filter 1

 Process line(s) (identification name/number)

Line 91-Dust Collector - 

Melters

 Equipment/process(es) controlled. Include emission 

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

Line 91 - EPN 21

 Latitude (decimal degrees, six decimal places) N32.38812

 Longitude (decimal degrees, six decimal places) W97.39713

 Stack or vent height (units) 60 ft

 Stack or vent diameter (units) 51.875 in

 Manufacturer and model Mac 144rpt252

 Date of original installation 1990

 Number of compartments 4

 Number of bags per compartment 135

 Filter material and coatings applied Polyester

 Fabric weight (oz/yd2) 16 oz

 Filter surface area (ft2) 6"x12' = 6 ft2 per bag

 Gas flow rate to filter (acfm @ °F) 40,318

 Inlet gas temperature (°F) 145

 Outlet gas temperature (°F) 145

 Inlet grain loading (gr/dscf) Not Available

 Outlet grain loading (gr/dscf) 0.0022

 Average stack opacity (%) < 5%

 Overall pressure drop (in. H2O gauge) 16

 Method and frequency of bag cleaning Continuous/Automatic

 Vendor guarantee on fabric filter efficiency (attach 

copy) None

 Quantity of solid waste collected (lbs/yr) 346,000

 Quantity of solid waste recycled (lbs/yr) None

 Quantity of solid waste disposed of (lbs/yr) 346,000

 Method of solid waste disposal RCRA Landfill

 Nature and frequency of preventive maintenance 

procedures

Weekly / monthly - Inspect 

and repair as needed

 Problems experienced with control device within the 

last five years; how were problems solved? None

 Continuous monitoring method(s) used to monitor 

performance, including parameters monitored Pressure Drop

 Plans to replace or upgrade fabric filter See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0008.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) N/A

 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?

 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-0008.xls
FORM C-6

AIR POLLUTION CONTROL

VI. High Velocity Air Filter (HVAF)

 For each HVAF: HVAF 1

 Process line(s) (identification name/number)

HIGH ENERGY AIR 

FILTRATION

 Equipment/process(es) controlled. Include emission 

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

EPN 3

 Latitude (decimal degrees, six decimal places) N32.38759

 Longitude (decimal degrees, six decimal places) W97.39491

 Stack or vent height (units) 52.75ft

 Stack or vent diameter (units) 59.875x45.875 in

 Manufacturer and model

Andersen 2000 Inc., Rotary 

Drum DF-54-VI

 Date of original installation 1964

 Inlet gas flow rate (acfm @ °F) 48,367 @ 145F

 Inlet gas temperature (°F) 145

 Outlet gas temperature (°F) 145

 Inlet grain loading (gr/dscf) Not Available

 Outlet grain loading (gr/dscf) 0.0058

 Average stack opacity (%) < 10%

 Water spray pressure (sdig), if applicable Not Applicable

 Water spray rate (gpm), if applicable Not Applicable

 Filter face velocity (acfm/ft2) 1,500 - 1,700

 Maximum pressure drop across mat (in. H2O gauge) 28

 Vendor guarantee on HVAF efficiency (attach copy) None

 Method and frequency of filter mad advancement Timer controlled

 Amount of wastewater generated (gpd) None

 Amount of wastewater recycled (gpd) None

 Amount of wastewater disposed of (gpd) None

 Method of wastewater disposal N/A

 Quantity of solid waste collected (lbs/yr) 2,000

 Quantity of solid waste recycled (lbs/yr) None

 Quantity of solid waste disposed of (lbs/yr) 2,000

 Method of solid waste disposal TCEQ Class II Landfill

 Nature and frequency of preventive maintenance 

procedures

Monthly - Inspect and clean 

thermocouples

 Problems experienced with control device within the 

last five years; how were problems solved? None

 Continuous monitoring method(s) used to monitor 

HVAF performance, including parameters monitored None

 Plans to replace or upgrade HVAF See CBI Submittal

EPA-HQ-OAR-2010-1042-DRAFT-0008.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) N/A

 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)

 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-0008.xls
FORM C-8

AIR POLLUTION CONTROL

VIII. Ventilation System 

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

 Process line(s) (identification name/number) N/A

 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-0008.xls
FORM C-9

AIR POLLUTION CONTROL

IX. Other 

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

 Process line(s) (identification name/number) Line 91 Oven-Ring Burner

 Equipment/process(es) controlled. Include emission point 

designations (e.g., E3, E4 from plot plan) EPN 20

 Latitude (decimal degrees, six decimal places) N32.38785

 Longitude (decimal degrees, six decimal places) W97.39664

 Stack or vent height (units) 59 feet

 Stack or vent diameter (units) 60 inches

 Description

Two burners of 5 MM 

BTU/hr each installed inside 

of the exhaust stack 

associated with EPN 20 

(L91 oven scrubber) with the 

purpose of reducing opacity 

from its source. 

EPA-HQ-OAR-2010-1042-DRAFT-0008.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. 

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

 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.

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.

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

EPA-HQ-OAR-2010-1042-DRAFT-0008.xls
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. See CBI Submittal

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. N/A

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. N/A

EPA-HQ-OAR-2010-1042-DRAFT-0008.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) 

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.

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)

Formaldehyde

Phenol

Methanol

Other organic HAP

EPA-HQ-OAR-2010-1042-DRAFT-0008.xls
FORM F-1 

COST

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

 For each Process Unit: Process Unit 1

 Process Unit ID All Units

 Process Line 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).

 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-0008.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-0008.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

 ($/yr) for each labor class See Above

EPA-HQ-OAR-2010-1042-DRAFT-0008.xls
 (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

EPA-HQ-OAR-2010-1042-DRAFT-0008.xls