Name: Stephen R. Aldridge

Title: Manager Corporate EH&S

Company: Knauf Insulation GmbH

Sign Date:

Name: Randal J. Tysar

Title: Senior Environmental Engineer

Company: BT Environmental Consulting, Inc.

Sign Date:

Permitted Facility Representative / Date Testing Company Representative / Date

Knauf Insulation Lanett, Alabama Residual Risk Emissions Test

Final Test Report 

for

/ /

Based on information and belief formed 

after reasonable inquiry, I certify that the 

statements and information in this test 

report are true, accurate, and complete.

I have reviewed all testing details and 

results in this test report and hereby 

certify that the test report is authentic 

and accurate.

Tuesday, January 18, 2011 Page 1 of 12
Knauf Insulation Lanett, Alabama Residual Risk Emissions Test

Facility Information:

Knauf Insulation GmbH, Lanett, AL

3502 43rd St

Lanett AL 36863

Contact: Steve Aldridge

Phone: 866-445-2363, ext. 8408

Fax:

Email: steve.aldridge@us.knaufinsulation.

com

Testing Company:

BT Environmental Consulting, Inc.

2615 Wolcott St

Ferndale MI 48220

Contact:Barry Boulianne

Phone: 313-449-2361

Fax:

Email: bboulianne@btecinc.com

Air Permit Number:

302-0011

Permitted Source ID/Name:

302-0011

Permitted Maximum Process Rate: Max. Normal Operation Process Rate: Target Process Test Rat

Description of the source (including control equipment). Please see the attachments for source or

 process flow diagram:

The processes evaluated by this emissions test program include the Line 621 melt furnace, the Line 621 forming and 

collection process, and the Line 621 curing oven/cooling process. The glass melt furnace fires natural gas and the 

furnace feed includes mixed batch and cullet. Emissions from the glass melt furnace are controlled by a dry 

electrostatic precipitator (ESP). Emissions from the forming and collection process are controlled by a wet ESP and 

emissions from the oven and cooling process are controlled by thermal oxidizers.

Industry/SCC/NAIS 327993

Sampling Location Information:

Test Parameter Information:

AFS #: 101700011 FRS #: 101700011

SCC / Description 30501202 Industrial Processes - Mineral Products - Fiberglass Manufacturing - Recuperative 

Furnace (Wool-type Fiber) 

The following state and federal regulations that apply to the proposed testing:

Location

Round

Duct

Diam.

Distance from 

upstream dist.

Distance from

downstream dist.

Number of

Traverse Ports

Equiv. 

Diam

Min.Travers 

Points

Rect. Duct 

Length /Width

621 Furnace 

Stack

47.52 0 0 0 0 0 2 12

Target

Parameter 

Test

Method

Number of

Test Runs

Test Run

Duration

Sample 

Location Points Comments

621 Furnace Chromium KnfLnAl - 0061 3 180 0

Stack

621 Furnace Hydrogen Fluoride Method 26A 3 60 0

Stack

Tuesday, January 18, 2011 Page 2 of 12
Knauf Insulation Lanett, Alabama Residual Risk Emissions Test

The following describes any modifications and/or deviations to the applicable test 

methods. If alternative methods were requested, see the attachments for documentation 

of request AND approval, including dates.

621 Furnace Hydrogen Chloride Method 26A 3 60 0

Stack

621 Furnace Selenium Method 29 3 180 0

Stack

621 Furnace Nickel Method 29 3 180 0

Stack

621 Furnace Manganese Method 29 3 180 0

Stack

621 Furnace Lead Method 29 3 180 0

Stack

621 Furnace Cobalt Method 29 3 180 0

Stack

621 Furnace Chromium Method 29 3 180 0

Stack

621 Furnace Cadmium Method 29 3 180 0

Stack

621 Furnace Beryllium Method 29 3 180 0

Stack

621 Furnace Arsenic Method 29 3 180 0

Stack

621 Furnace Antimony Method 29 3 180 0

Stack

621 Furnace Filterable Particulate Method 29 3 180 0

Stack

Tuesday, January 18, 2011 Page 3 of 12
Knauf Insulation Lanett, Alabama Residual Risk Emissions Test

Sampling / Stack Data Results Summary

Location 621 Furnace Stack - KnfLnAl - 0061

Average

Run Number 1 2 3 

Test Date 10/20/2010 10/20/2010 10/20/2010 

Run Start Time 9:32:00 AM 1:20:00 PM 8:20:00 AM 

Run Finish Time 12:47:00 PM 4:31:00 PM 11:25:00 AM 

Net Run Time, minutes 180 180 180 

Dry Gas Meter Volume Sampled, dscf 123.796 122.216 124.976 123.663

Moisture Content of Stack Gas, % 15.56 16.16 15.49 15.737

Moisture Saturation at Stack Gas Temperature, % 100.00 100.00 100.00 100.000

Carbon Dioxide, % 8.42 8.35 8.99 8.587

Oxygen, % 18.58 18.8 18.54 18.640

Average Stack Gas Temperature, °F 518.56 516.89 507.86 514.437

Dry Volumetric Flow Rate, dry scfm 8,521.8 8,203.5 8,255.7 8,327.000

Actual Wet Volumetric Flue Gas Flow Rate, acfm 19,198.2 18,607.0 18,437.1 18,747.433

Percent Isokinetic of Sampling Rate, % 95.9 98.3 99.9 98.033

F-Factor, dscfm/MMBtu @ %O2 0 0 0 0.000

Fw 0 0 0 0.000

Fc 0 0 0 0.000

Tuesday, January 18, 2011 Page 4 of 12
Knauf Insulation Lanett, Alabama Residual Risk Emissions Test

Location 621 Furnace Stack - Method 26A

Average

Run Number 1 2 3 

Test Date 10/19/2010 10/19/2010 10/19/2010 

Run Start Time 9:52:00 AM 12:15:00 

PM

2:35:00 PM 

Run Finish Time 10:58:00 AM 1:19:00 PM 3:38:00 PM 

Net Run Time, minutes 60 60 60 

Dry Gas Meter Volume Sampled, dscf 43.844 43.637 44.400 43.960

Moisture Content of Stack Gas, % 13.89 13.26 12.77 13.307

Moisture Saturation at Stack Gas Temperature, % 100.00 100.00 100.00 100.000

Carbon Dioxide, % 9.47 9.3 9.08 9.283

Oxygen, % 19.2 18.86 18.96 19.007

Average Stack Gas Temperature, °F 520.75 522.67 524.42 522.613

Dry Volumetric Flow Rate, dry scfm 8,674.4 8,730.2 9,063.6 8,822.733

Actual Wet Volumetric Flue Gas Flow Rate, acfm 19,338.6 19,279.5 19,959.3 19,525.800

Percent Isokinetic of Sampling Rate, % 97.8 96.7 94.8 96.433

F-Factor, dscfm/MMBtu @ %O2 0 0 0 0.000

Fw 0 0 0 0.000

Fc 0 0 0 0.000

Location 621 Furnace Stack - Method 29

Average

Run Number 1 2 3 

Test Date 10/20/2010 10/20/2010 10/21/2010 

Run Start Time 9:32:00 AM 1:20:00 PM 8:20:00 AM 

Run Finish Time 12:47:00 PM 4:31:00 PM 11:30:00 AM 

Net Run Time, minutes 180 180 180 

Dry Gas Meter Volume Sampled, dscf 124.246 128.854 126.174 126.425

Moisture Content of Stack Gas, % 13.35 12.84 13.49 13.227

Moisture Saturation at Stack Gas Temperature, % 100.00 100.00 100.00 100.000

Carbon Dioxide, % 8.42 8.35 8.99 8.587

Oxygen, % 18.6 18.8 18.54 18.647

Average Stack Gas Temperature, °F 518.97 516.83 507.33 514.377

Dry Volumetric Flow Rate, dry scfm 8,519.1 9,053.8 8,844.4 8,805.767

Actual Wet Volumetric Flue Gas Flow Rate, acfm 18,710.5 19,752.4 19,264.7 19,242.533

Percent Isokinetic of Sampling Rate, % 98.0 95.7 95.9 96.533

F-Factor, dscfm/MMBtu @ %O2 0 0 0 0.000

Fw 0 0 0 0.000

Fc 0 0 0 0.000

Tuesday, January 18, 2011 Page 5 of 12
Knauf Insulation Lanett, Alabama Residual Risk Emissions Test

Tuesday, January 18, 2011 Page 6 of 12
Knauf Insulation Lanett, Alabama Residual Risk Emissions Test

Emissions Summary

Location: 621 Furnace Stack - KnfLnAl - 0061

Compound: Chromium

Average

RunNumber 1 2 3 

Mass_mg 0.02725 0.00845 0.01125 0.016

Elb/hr 2.48E-04 7.50E-05 9.83E-05 0.000

mg/dscm 7.77E-03 2.44E-03 3.18E-03 0.004

Location: 621 Furnace Stack - Method 26A

Compound: Hydrogen Chloride

Average

RunNumber 1 2 3 

Mass_mg 0.9 0.73 0.7 0.777

Elb/hr 2.36E-02 1.93E-02 1.89E-02 0.021

mg/dscm 7.25E-01 5.91E-01 5.57E-01 0.624

Compound: Hydrogen Fluoride

Average

RunNumber 1 2 3 

Mass_mg 2.3 2.1 2.3 2.233

Elb/hr 6.02E-02 5.56E-02 6.21E-02 0.059

mg/dscm 1.85E+00 1.70E+00 1.83E+00 1.793

Location: 621 Furnace Stack - Method 29

Compound: Antimony

Average

RunNumber 1 2 3 

Mass_mg 0.002 0.002 0.002 0.002

Elb/hr 1.81E-05 1.86E-05 1.85E-05 0.000

mg/dscm 5.69E-04 5.48E-04 5.60E-04 0.001

Compound: Arsenic

Average

RunNumber 1 2 3 

Mass_mg 0.002 0.002 0.002 0.002

Elb/hr 1.81E-05 1.86E-05 1.85E-05 0.000

mg/dscm 5.69E-04 5.48E-04 5.60E-04 0.001

Compound: Beryllium

Average

RunNumber 1 2 3 

Mass_mg 0.0005 0.0005 0.0005 0.001

Elb/hr 4.53E-06 4.65E-06 4.64E-06 0.000

mg/dscm 1.42E-04 1.37E-04 1.40E-04 0.000

Compound: Cadmium

Average

RunNumber 1 2 3 

Mass_mg 0.002 0.00197 0.00126 0.002

Elb/hr 1.81E-05 1.83E-05 1.17E-05 0.000

Tuesday, January 18, 2011 Page 7 of 12
Knauf Insulation Lanett, Alabama Residual Risk Emissions Test

mg/dscm 5.69E-04 5.40E-04 3.53E-04 0.000

Compound: Chromium

Average

RunNumber 1 2 3 

Mass_mg 0.0542 0.0856 0.043 0.061

Elb/hr 4.92E-04 7.96E-04 3.99E-04 0.001

mg/dscm 1.54E-02 2.35E-02 1.20E-02 0.017

Compound: Cobalt

Average

RunNumber 1 2 3 

Mass_mg 0.0005 0.0005 0.0005 0.001

Elb/hr 4.53E-06 4.65E-06 4.64E-06 0.000

mg/dscm 1.42E-04 1.37E-04 1.40E-04 0.000

Compound: Filterable Particulate

Average

RunNumber 1 2 3 

Mass_mg 10.7 13 5.4 9.700

Elb/hr 9.70E-02 1.21E-01 5.01E-02 0.089

mg/dscm 3.04E+00 3.56E+00 1.51E+00 2.703

Compound: Lead

Average

RunNumber 1 2 3 

Mass_mg 0.0177 0.0236 0.0124 0.018

Elb/hr 1.61E-04 2.19E-04 1.15E-04 0.000

mg/dscm 5.03E-03 6.47E-03 3.47E-03 0.005

Compound: Manganese

Average

RunNumber 1 2 3 

Mass_mg 0.0038 0.0038 0.0038 0.004

Elb/hr 3.45E-05 3.53E-05 3.52E-05 0.000

mg/dscm 1.08E-03 1.04E-03 1.06E-03 0.001

Compound: Nickel

Average

RunNumber 1 2 3 

Mass_mg 0.0047 0.0038 0.0025 0.004

Elb/hr 4.26E-05 3.53E-05 2.32E-05 0.000

mg/dscm 1.34E-03 1.04E-03 7.00E-04 0.001

Compound: Selenium

Average

RunNumber 1 2 3 

Mass_mg 0.0074 0.005 0.0063 0.006

Elb/hr 6.71E-05 4.65E-05 5.84E-05 0.000

mg/dscm 2.10E-03 1.37E-03 1.76E-03 0.002

Tuesday, January 18, 2011 Page 8 of 12
Knauf Insulation Lanett, Alabama Residual Risk Emissions Test

Process Run Data

APCD Run Data

Process Lab Run Data

Tuesday, January 18, 2011 Page 9 of 12
Knauf Insulation Lanett, Alabama Residual Risk Emissions Test

Sampling / Stack Data Results Detail

Location 621 Furnace Stack - KnfLnAl - 0061

Average

Run Number 1 2 3 

Test Date 10/20/2010 10/20/2010 10/20/2010 

Run Start Time 9:32:00 AM 1:20:00 PM 8:20:00 AM 

Run Finish Time 12:47:00 PM 4:31:00 PM 11:25:00 AM 

Net Traversing Points 36 36 36 

Net Run Time, minutes 180 180 180 

Nozzle Diameter, inches 0.436 0.436 0.436 0.436

Pitot Tube Coefficient 0.809 0.809 0.809 0.809

Dry Gas Meter Calibration Factor 1.013 1.013 1.013 1.013

Barometric Pressure, inches of Mercury 29.18 29.14 29.09 29.137

Average Orifice Meter Differential, inches H2O 1.55 1.44 1.43 1.473

Dry Gas Meter Volume Sampled, cubic feet 126.921 126.937 128.164 127.341

Average Dry Gas Meter Temperature, °F 76.89 83.01 75.22 78.373

Dry Gas Meter Volume Sampled, dscf 123.796 122.216 124.976 123.663

Total Moisture Liquid collected, g 484.8 500.5 486.5 490.600

Volume of Water Vapor, standard cubic feet 22.82 23.56 22.90 23.093

Moisture Content of Stack Gas, % 15.56 16.16 15.49 15.737

Moisture Saturation at Stack Gas Temperature, % 100.00 100.00 100.00 100.000

Dry Mole Fraction 0.8444 0.8384 0.8451 0.843

Carbon Dioxide, % 8.42 8.35 8.99 8.587

Oxygen, % 18.58 18.8 18.54 18.640

Carbon Monoxide & Nitrogen, % 73 72.85 72.47 72.773

Fuel Factor 0.28 0.25 0.26 

Dry Molecular Weight, lb/lb-Mole 30.09 30.09 30.18 30.120

Wet Molecular weight, lb/lb-Mole 28.21 28.14 28.29 28.213

Flue Gas Static Pressure, inches of H2O -0.4 -0.4 -0.4 -0.400

Absolute Flue Gas Pressure, inches of Mercury 29.15 29.11 29.06 29.107

Average Stack Gas Temperature, °F 518.56 516.89 507.86 514.437

Average Velocity Head, inches of H2O 0.1185923443

51768

0.111128808

998679

0.1105213299

9308

0.113

Average Stack Gas Velocity, feet/second 25.98 25.18 24.95 25.370

Stack Cross-Sectional Area, square feet 12.316 12.316 12.316 12.316

Dry Volumetric Flow Rate, dry scfm 8,521.8 8,203.5 8,255.7 8,327.000

Actual Wet Volumetric Flue Gas Flow Rate, acfm 19,198.2 18,607.0 18,437.1 18,747.433

Percent Isokinetic of Sampling Rate, % 95.9 98.3 99.9 98.033

Percent Excess Air, % 2,685.0 4,347.8 3,131.3 3,388.033

F-Factor, dscfm/MMBtu @ %O2 0 0 0 0.000

Round Duct Diameter, inches 47.52 47.52 47.52 

Rectangular Duct Width, inches 0 0 0 

Rectangular Duct Length, inches 0 0 0 

Fw 0 0 0 0.000

Fc 0 0 0 0.000

Tuesday, January 18, 2011 Page 10 of 12
Knauf Insulation Lanett, Alabama Residual Risk Emissions Test

Location 621 Furnace Stack - Method 26A

Average

Run Number 1 2 3 

Test Date 10/19/2010 10/19/2010 10/19/2010 

Run Start Time 9:52:00 AM 12:15:00 PM 2:35:00 PM 

Run Finish Time 10:58:00 AM 1:19:00 PM 3:38:00 PM 

Net Traversing Points 12 12 12 

Net Run Time, minutes 60 60 60 

Nozzle Diameter, inches 0.441 0.441 0.441 0.441

Pitot Tube Coefficient 0.802 0.802 0.802 0.802

Dry Gas Meter Calibration Factor 1.011 1.011 1.011 1.011

Barometric Pressure, inches of Mercury 28.98 29.1 29.08 29.053

Average Orifice Meter Differential, inches H2O 1.58 1.57 1.67 1.607

Dry Gas Meter Volume Sampled, cubic feet 45.982 46.083 46.743 46.269

Average Dry Gas Meter Temperature, °F 84.42 90.46 88.50 87.793

Dry Gas Meter Volume Sampled, dscf 43.844 43.637 44.400 43.960

Total Moisture Liquid collected, g 150.3 141.6 138 143.300

Volume of Water Vapor, standard cubic feet 7.07 6.67 6.50 6.747

Moisture Content of Stack Gas, % 13.89 13.26 12.77 13.307

Moisture Saturation at Stack Gas Temperature, % 100.00 100.00 100.00 100.000

Dry Mole Fraction 0.8611 0.8674 0.8723 0.867

Carbon Dioxide, % 9.47 9.3 9.08 9.283

Oxygen, % 19.2 18.86 18.96 19.007

Carbon Monoxide & Nitrogen, % 71.33 71.84 71.96 71.710

Fuel Factor 0.18 0.22 0.21 

Dry Molecular Weight, lb/lb-Mole 30.28 30.24 30.21 30.243

Wet Molecular weight, lb/lb-Mole 28.57 28.62 28.65 28.613

Flue Gas Static Pressure, inches of H2O -0.4 -0.4 -0.5 -0.433

Absolute Flue Gas Pressure, inches of Mercury 28.95 29.07 29.04 29.020

Average Stack Gas Temperature, °F 520.75 522.67 524.42 522.613

Average Velocity Head, inches of H2O 0.1229033201

35481

0.122554599

623097

0.1311641589

12513

0.126

Average Stack Gas Velocity, feet/second 26.17 26.09 27.01 26.423

Stack Cross-Sectional Area, square feet 12.316 12.316 12.316 12.316

Dry Volumetric Flow Rate, dry scfm 8,674.4 8,730.2 9,063.6 8,822.733

Actual Wet Volumetric Flue Gas Flow Rate, acfm 19,338.6 19,279.5 19,959.3 19,525.800

Percent Isokinetic of Sampling Rate, % 97.8 96.7 94.8 96.433

Percent Excess Air, % -5,204.9 17,832.8 50,641.0 21,089.633

F-Factor, dscfm/MMBtu @ %O2 0 0 0 0.000

Round Duct Diameter, inches 47.52 47.52 47.52 

Rectangular Duct Width, inches 0 0 0 

Rectangular Duct Length, inches 0 0 0 

Fw 0 0 0 0.000

Fc 0 0 0 0.000

Tuesday, January 18, 2011 Page 11 of 12
Knauf Insulation Lanett, Alabama Residual Risk Emissions Test

Location 621 Furnace Stack - Method 29

Average

Run Number 1 2 3 

Test Date 10/20/2010 10/20/2010 10/21/2010 

Run Start Time 9:32:00 AM 1:20:00 PM 8:20:00 AM 

Run Finish Time 12:47:00 PM 4:31:00 PM 11:30:00 AM 

Net Traversing Points 36 36 36 

Net Run Time, minutes 180 180 180 

Nozzle Diameter, inches 0.432 0.432 0.432 0.432

Pitot Tube Coefficient 0.802 0.802 0.802 0.802

Dry Gas Meter Calibration Factor 1.011 1.011 1.011 1.011

Barometric Pressure, inches of Mercury 29.18 29.14 29.12 29.147

Average Orifice Meter Differential, inches H2O 1.39 1.49 1.45 1.443

Dry Gas Meter Volume Sampled, cubic feet 130.320 135.620 131.147 132.362

Average Dry Gas Meter Temperature, °F 87.97 89.25 81.99 86.403

Dry Gas Meter Volume Sampled, dscf 124.246 128.854 126.174 126.425

Total Moisture Liquid collected, g 406.9 403.2 418 409.367

Volume of Water Vapor, standard cubic feet 19.15 18.98 19.68 19.270

Moisture Content of Stack Gas, % 13.35 12.84 13.49 13.227

Moisture Saturation at Stack Gas Temperature, % 100.00 100.00 100.00 100.000

Dry Mole Fraction 0.8665 0.8716 0.8651 0.868

Carbon Dioxide, % 8.42 8.35 8.99 8.587

Oxygen, % 18.6 18.8 18.54 18.647

Carbon Monoxide & Nitrogen, % 72.98 72.85 72.47 72.767

Fuel Factor 0.27 0.25 0.26 

Dry Molecular Weight, lb/lb-Mole 30.09 30.09 30.18 30.120

Wet Molecular weight, lb/lb-Mole 28.48 28.54 28.54 28.520

Flue Gas Static Pressure, inches of H2O -0.4 -0.4 -0.4 -0.400

Absolute Flue Gas Pressure, inches of Mercury 29.15 29.11 29.09 29.117

Average Stack Gas Temperature, °F 518.97 516.83 507.33 514.377

Average Velocity Head, inches of H2O 0.1156572306

74047

0.129291465

483988

0.1241020339

60327

0.123

Average Stack Gas Velocity, feet/second 25.32 26.73 26.07 26.040

Stack Cross-Sectional Area, square feet 12.316 12.316 12.316 12.316

Dry Volumetric Flow Rate, dry scfm 8,519.1 9,053.8 8,844.4 8,805.767

Actual Wet Volumetric Flue Gas Flow Rate, acfm 18,710.5 19,752.4 19,264.7 19,242.533

Percent Isokinetic of Sampling Rate, % 98.0 95.7 95.9 96.533

Percent Excess Air, % 2,789.8 4,347.8 3,131.3 3,422.967

F-Factor, dscfm/MMBtu @ %O2 0 0 0 0.000

Round Duct Diameter, inches 47.52 47.52 47.52 

Rectangular Duct Width, inches 0 0 0 

Rectangular Duct Length, inches 0 0 0 

Fw 0 0 0 0.000

Fc 0 0 0 0.000

Tuesday, January 18, 2011 Page 12 of 12