Enclosure 2a

Owner Name: _____ American Excelsior ________ Facility Name: __ American Excelsior
________ Process Unit ID: _______ P38 _________________

Hours Per (e.g., week, month, year) Machine 33 1995 $700,500 10 years 10,500 10 260 Machine 43 2001 $190,000 15 years 4250 8 260 PART IV. GENERAL FLEXIBLE POLYURETHANE FORAM PRODUCTION INFORMATION

Process unit ID Year unit

originally installed Original captial

cost of unit(s) Remaining useful life

of unit Maximum design

capacity (e.g., lbs/day) Please complete the following questions for each Flexible Polyurethane Foam Production process unit. You are not expected to generate new information for this survey. Only supply data that are readily available to you.
Typical unit operation 1. Please provide the following information for each Flexible Polyurethane Foam Production process unit: a. Provide general information for each process unitEnclosure 2a

Owner Name: _____ American Excelsior ________ Facility Name: __ American Excelsior
________ Process Unit ID: _______ P38 _________________

NA trains. b. Provide information on upgrades to each flexible polyurethane foam production process unit and associated air pollution control Description of upgrades made to air pollution control devices associated with the Description of upgrades made to the process unit Year(s) upgrade was made Process unit ID Year(s) upgrade was madeEnclosure 2a

Owner Name: _____ American Excelsior ________ Facility Name: __ American Excelsior
________ Process Unit ID: _______ P38 _________________

Process Unit ID Total operating and

maintenance costs 2008 2009 2010 Machine 33 18750 16900 43740 Macine 43 7518 10525 8452 c. Using the format on this page, include operating and maintenance cost information for each process unit. Definitions for different types of costs are taken from EPA Air Pollution Control Cost Manual at http://epa.gov/ttn/catc/products.html#cccinfoOwner Name: _____ American Excelsior ________ Facility Name: __ American Excelsior
________

Process Unit ID: _______ P38 _________________ 2. Include yearly emissions information in the following table (include source of information). Emission Point Process

Unit ID HAP Pollutant Tons per year 2006 * Tons per year

2007 * Tons per year

2008 * S40 P38 4,4 methylene diphenyl From Injection Modling 0.005565 0.005565 0.003450 diisocyanate (MDI) CAS No. 101-68-8 From Tanker Transfer 3.29E-06 3.34E-06 2.30E-06 0.005568 0.005568 0.003452 

## * Above caculated using "A. Formula" from Society of the Plastics Industry 

## * A. Formula: W = 25.4 * (P T * M T ) T ( ° K ) Society of the Plastics Industry 

## ** From: Releases of MDI and TDI from flexible foam moulding processes. Isocyanante Emissions Toolbox American Chemistry Council; Center for Poly Industries Emission factor: 0.0006% MDI lost/emitted as a percent of use. All liquid transfer emissions to Storage Tank based on worst case (100% MDI) and using the US EPAs equation adopted from AP-42 for evaporative loss using the normal service saturation factor. unit. Include storage tanks or any auxiliary equipment on site, per unit ID and label each as type of

Total ->Calculation Example: LLvoc (Lbs VOC/1000gal) = 12.46 * (S * P psai * M * Q) / T REnclosure 2a

Tons per year 2009 ** Tons per year

2010 ** 0.000255 0.000278 2.34E-06 2.42E-06 0.000257 0.000280 ** Caculated using published factors from AmerChemCncl * μ 0.78 * A (<-0.00000137)


## ** From: Releases of MDI and TDI from flexible foam moulding processes. American Chemistry Council; Center for Poly Industries Emission factor: 0.0006% MDI lost/emitted as a percent of use. All liquid transfer emissions to Storage Tank based on worst case (100% MDI) and using the US EPAs equation adopted from AP-42 for evaporative loss using the normal service saturation factor. unit. Include storage tanks or any auxiliary equipment on site, per unit ID and label each as type ofCalculation Example: LLvoc (Lbs VOC/1000gal) = 12.46 * (S * P psai * M * Q) / T RXylenes (Mixture of o, m, and p Isomers) Methyl Isobutyl Ketone 2,4-Toluene Diisocyanate Methylene Chloride Toluene Ethyl Benzene Styrene Diethanolamine Benzene Bis(2-Ethylhexyl)Phthalate Glycol Ethers Methanol 4,4'-Methylenediphenyl Diisocyanate p-Dioxane 1,2-Epoxybutane Cumene Vinyl Acetate Triethylamine Chloroform Acetonitrile Phenol Cyanide & CompoundsHexane Formaldehyde p-Xylene Acetaldehyde Acrylonitrile Ethylene GlycolEnclosure 2a Owner Name: _____ American Excelsior ________ Facility Name: __ American Excelsior
________ Process Unit ID: _______ P38 _________________ No testing conducted for P38 Injection Modling

e. Submit a copy of the test reports. f. For pollutants measured with continuous emissions monitoring systems (CEMS), please submit a copy of the most recent Relative Accuracy Test Audit (RATA) for the last 30 day period including those days where manual testing was conducted. 3. Provide information on each emission test conducted at each specific process unit. Please copy this page and provide the following information for each test conducted at anytime in the last 5 years. a. Identify the Process Unit ID: ___ No testing conducted for P38 Injection Modling. b. Describe emission release point(s) that were tested: ___________________na_____________________________ c. Date of test: _______________na_____________________ d. Specify the test method(s) used: ____________________________na_____________________________________

_________________________________________________________________________________________________Enclosure 2a

Owner Name: _____ American Excelsior ________ Facility Name: __ American Excelsior
________ Process Unit ID: _______ P38 _________________ 4. For each flexible polyurethane foam production process unit, provide the following information regarding air pollution control devices. Please copy this page and provide the following information for each unit: a. Process Unit ID: ____ P38 Injection Molding

___________________________________________

(e.g., ductwork, piping, foundation/supports, site preparation): __________________________

___________________________________________________________________________________ __________________________________________na_________________________________________
___________________________________________________________________________________ __________________________________________________________________________________ b. Does the process unit have a control device that reduces air pollution : _____ Yes _ XX __ No

__________________________________________________________________________________ __________________________________________________________________________________ d. Type of control device: __________________na___________________________________________ e. Year installed: __________________________na__________________________________________

i. List the elements that are included in the installed cost estimate in question IV.5.h c. Describe the release point(s) that are being controlled (e.g., equipment or unit operation where the release point is located): __________________________________________________

__________________________________________________________________________________ _________na_________________________________________________________________________

f. Manufacturer: ___________________________na__________________________________________ g. Model No: ______________________________na_________________________________________ ________________________________________na__________________________________________ h. Original installed cost of the control device (capital cost of the control plus installation cost):Operating cost information 2008 2009 2010 Control device ID: Total operating costs Electricity costs Wastwater treatment costs Fuel costs Water costs Waste disposal costs Process unit operating labor costs Monitoring, recordkeeping, and reporting Other (please describe):

________________ Other (please describe):

________________ control device. j. Use the following table to provide the annual cost for operating and maintenance of eachEnclosure 2a

Owner Name: _____ American Excelsior ________ Facility Name: __ American Excelsior
________ Process Unit ID: _______ P38 _________________

Process unit ID Measures or modification made to minimuze emissions Estimated emission reduction (lb/yr) 5. For each process unit identify measures (e.g., annual tune-ups or burners, good comubtion practices, pollution prevention measures, or any other emission control approaches that reduce HAP emissions) or modifications made to the process unit to reduce emissions:
na... None: Process emits very low amount of HAP emissions.Enclosure 2a

Owner Name: _____ American Excelsior ________ Facility Name: __ American Excelsior
________ Process Unit ID: _______ P38 _________________
Emission reduction technique descriptions Pollutants affected Reduction efficiency

________________________ _______________________ ____________________

________________________ _______________________ ____________________

________________________ _______________________ ____________________

________________________ _______________________ ____________________

________________________ _______________________ ____________________

na ___________________________________________________________________________________________ e. At what frequency is parameter monitor quality assurance/control (e.g., calibration) performed?

7. Please submit a copy of any cost information you have for the modification or emission reduction method (other than add-on control devices) listed above. _____na___________________________________________________________________________________
___________________________________________________________________________________________ f. What is annual parameter monitoring cost? ______na__________________________________________________________________________________ 6. Other emission reduction techniques. Include any information about changes made in raw material usage to

_____na___________________________________________________________________________________ reduce emissions, such as substitutions or product reformulation. a. Complete fo each emission reduction technique utilized that is not a contro device.

b. What parameters are monitored to ensure operation of the emission reduction technique? ______________na_____________________________________________________________________________ c. At what frequency is parameter monitoring done? _____na______________________________________ d. Describe initial and ongoing parameter monitoring quality assurance/control: na... None: Process emits very low amount of HAP emissions.Enclosure 2a

Owner Name: _____ American Excelsior ________ Facility Name: __ American Excelsior
________ Process Unit ID: _______ P38 _________________

Emission source(s) causing event Description

of event Permit

conditions exceeded (Y/N) Date of

Event Duration

of each event (hours) Was the event

covered by a contingency plan for controlling emissions? (Y/N) Estimates

of emissions during event (pounds) Basis for

emissions estimate Any monitoring

data or control system parameter monitoring collected during event? (Y/N)
No emissions are expected from start up/shut down events that would not be accounted for by calculating MDI emissions from polyol use a. Please indicate number of times over the last 3 years that a shutdown and start-up event has occurred: ____________________________________________ b. Complete the following table for each shutdown and start-up event occurring over the last three years. 8. Please provide the following information for each process unit during start-up and shutdown operation:Owner Name: _____ American Excelsior ________ Facility Name: __ American Excelsior
________

Process Unit ID: _______ P38 _________________

_____ na
________________________________________________________________________

__________________________________________________________________________________

of the flexible polyuretuane foam production process unit. k. Are you required to submit periodic and immediate start-up and shutdown reports (either stand-alone or contrained within the periodic excess emissions report) to your permitting aurhority? _____ No

____________________________________________________ _____ na
______________________________________________________________________ _______________________________________________________________________________ h. Please identify the emissions test method(s) used during start-up or shutdown.

_______________________________________________________________________________ _____ na
________________________________________________________________________ _______________________________________________________________________________

_______________________________________________________________________________ j. Please submit a copy of any test data you have conducted during any start-up or shutdown _______________________________________________________________________________ i. What were the test conditions at the time of testing ? ________________________________

_______ na
_____________________________________________________________________ _______________________________________________________________________________ f. Do you have test data that show emissions durint start-up or shutdown? __ Yes __ No g. If yes, when and why did you conduct such testing? __________________________________ Enclosure 2a c. Please list the procedures that are followed or any activities that occur during start-up and shutdown at this process unit to minimize emissions (e.g., turn off unit, monitor pressure): d. Is the emission profile of the flexible polyurethane foam production unit differenet during start-up and shutdown than during normal operating conditions? _____ Yes x__No e. If the answer to Part IV 9.d. is yes, please explain, in detail, how and why emissions are different

______ na
_______________________________________________________________________

__________________________________________________________________________________Owner Name: _____ American Excelsior ________ Facility Name: __ American Excelsior
________ Process Unit ID: _______ P38 _________________



### Longitude Latitude S40 P38 -87.74612904 43.72046644 S40 consists of: Exhaust Fan#1 

### 14 5500 91.667 65.664 Exhaust Fan#2 

### 14 10500 175.000 125.358 Exhaust Fan#11 

### 14 5500 91.667 65.664 9. Stack Relase Parameters for Emission Points Please provide the following information for all emission release points for use in righ modeling 

### Height of release point (feet) Exit of velocity of vent release point (feet/second) Discharge Flow Rate release point (cfs) Discharge Flow Rate release point (cfm) Location of release point (decimal degrees, minimum 5 digits beyond

decimal) Emission Point Process Unit IDEnclosure 2a



### ambient 1.396 1.3333 ambient 1.396 1.3333 ambient 1.396 1.3333 9. Stack Relase Parameters for Emission Points Please provide the following information for all emission release points for use in righ modeling 

### Exit temperature of vent/flue gas (F) Diameter of release point (feet) X-sectional area of release point (ft2)Owner Name: _____ American Excelsior ________ Facility Name: __ American Excelsior
________

Process Unit ID: _______ P38 _________________



### Height of release point Release Height Longitude Latitude (ft) (ft) Because of negative pressure in injection area, emissions are drawn into system hoods and stacks for point discharge; only insignificant amounts of fugitive emissions are expected.

Notes on Modeling Data: Coordinates: For geographic coordinates, provide either latitude and longitude or UTM coordinates with zone. Latitude and longitude should be provided in decimal degrees, with 6 digits to right of decimal point, and an indication of the associated NAD (North American Datum, either NAD27 or NAD83. If left blank, NAD83 will be Latitude: Measure in decimal degrees of the angular distance on a meridian north or south of the equator. Positive (+) data point for N. America. Include (+) sign. Ex. +78.123456. For point sources this represents the center of the source; for fugitive sources this is the southwest corner if thefugitive angle is zero, or the western most corner if the fugitive angle is greater than zero. Longitude: Measure in decimal degrees of the angular distance on a meridan east or west of the prime meridian Negative (-) data point for N. American. Includle (-) sign. Ex. -123.234561. For point sources this represents the center of the source; for fugitive sources this is the southwest corner if the fugitive angle is zero, or the western most corner if the fugitive angle is greater than zero. 10. Non point releases. Please include a listing of fugitive releases, including the following information per release point. Please include "no releases" if this question does not



### Process Unit ID apply. Notes on modeling data definitions are below. 

### Location of release point (decimal degrees, minimum 5 digits beyond decimal) Emission PointAngle of Rotation: Angle of rotation specifies the rotation of the source from north

(in the clockwise direction). The location coordinates (UTM or latitude and longitude) should reflect the southwest corner of the area source. The x-dimension should reflect the length of the source in the easterly direction, or in the southeasterly direction if the source is rotated. The y-dimension should reflect the length in the northerly direction, or the northeasterly direction if the source is rotated. Longitude: Measure in decimal degrees of the angular distance on a meridan east or west of the prime meridian Negative (-) data point for N. American. Includle (-) sign. Ex. -123.234561. For point sources this represents the center of the source; for fugitive sources this is the southwest corner if the fugitive angle is zero, or the western most corner if the fugitive angle is greater than zero.

### Angle of Rotation

x (length, ft) y (width, ft) (degrees) Because of negative pressure in injection area, emissions are drawn into system hoods and stacks for point discharge; only insignificant amounts of fugitive emissions are expected. 10. Non point releases. Please include a listing of fugitive releases, including the following information per release point. Please include "no releases" if this question does not apply. Notes on modeling data definitions are below.



### Dimension of SourceEnclosure 2a

Owner Name: _____ American Excelsior ________ Facility Name: __ American Excelsior
________ Process Unit ID: _______ P38 _________________
b. Please list the pollutants that the scrubber is intended to reduce or remove. 11. Scrubber a. Does the flexible polyurethane foam production process unit have a scurbber?

_____ Yes __ XX _ No

o. What control devices are downstream of the scrubber? ____________na__________________ l. Average outlet gas temperature for each scurbber: _______________na_______________ o F m. Please describe the source and quality of the water fed to the scrubber (e.g., effluent water with a total solids content of _____): _________________________________________

_______________________________________________________________________________ _____________na________________________________________________________________
_______________________________________________________________________________ _______________________________________________________________________________ n. What control devices are upstream of the scrubber? ______________na_________________ i. Scrubber water flow: ______________________________na_________________ gals/min (?) j. Scrubber pressure drop (across each scrubber--provide units): ________na_______________ k. Mist eliminator: _____ Yes _____ No _________________________________ na
____________________________________________ _______________________________________________________________________________ c. Type of scrubber: _________________________na____________________________________ d. Design pollutant-laden gas inlet flow rate: ___--___acfm e. Design pollutant-laden gas inlet temperature: ___--_____ o F f. Scrubbing medium (describe): _____________________na_____________________________ g. Influent scrubbing medium pH: ____________________na_____________________________ h. Effluent scurbbing medium pH: ____________________na_____________________________Enclosure 2a

Owner Name: _____ American Excelsior ________ Facility Name: __ American Excelsior
________ Process Unit ID: _______ P38 _________________
Legal Owner Name: Facility Name: na Process Unit ID: na Process Unit ID for controlled processes: na Stack or Vent Height (ft) na Stack or Vent Diameter (ft) na Manufacturer/Model na Original Installation Date na Gas flow rate to condenser (acfm) na Inlet gas temerature ( o F) na Compound Name na Volume Fraction na Compound Name na Volume Fraction na Compound Name na Volume Fraction na Compound Name na Volume Fraction na List all monitoring methods used, including parameters and frequency Describe any plans to replace or upgrade the adsorber 12. Carbon Adsorber Please include a copy of this table for each carbon adsorber controlling emissions from flexible polyurethane foam production process unit. CARBON ADSORBER

Organic compounds in inlet gas stream

Vendor guarantee on adsorber efficient (attach copy) Describe preventative maintenance procedures and frequencyEnclosure 2

2010 2009 2008 2010 2009 2008 Injection Molding Polyol Part A 205,785.50 188,471.58 184,578.88 <- Pounds Polyol Part B 382,567.39 380,689.33 374,770.08 <- Pounds Total as Foam Produced -> 588,352.89 569,160.91 559,348.96 <- Pounds 2000 2500 2500 Hours/Year Process unit name Production Amount Production units (e.g., gallons, pounds) 

### PART III. FEEDSTOCK, RAW MATERIAL, AND PRODUCTION INFORMATION 1. Please complete the following table for production information for each process unit. Average time each product was manufactured (e.g., days, or

hours) Process unit nameEnclosure 2
2010 2009 2008 Injection Molding Polyol Part A Pounds -> 205,785.50 188,471.58 184,578.88 Polyol Part B Pounds -> 382,567.39 380,689.33 374,770.08 Total as Raw Material used -> Pounds -> 588,352.89 569,160.91 559,348.96 2. Please complete the following table for Raw Materials/feedstocks entering each process unit. Include only HAP-containing feedstock. Process unit name Raw material/feedstock Raw material/ feedstock amount Raw material/feedstockEnclosure 2

Raw material products/feedstock Auxiliary Blowing Agents Chemical Compounds % of each chemical compound Polyol Part A none 4,4 methylene diphenyl 45.0% Polyol Part B none diisocyanate (MDI) 0.0% CAS No. 101-68-8 3. Provide composition information for feedstock/raw materials.Adhesive Name HAP Contained HAP Content (wt%)

4. Are any HAP-containing adhesivies utilized in repair of foam as part of the production process? No Adhesive is used in repair of foam for this process.Enclosure 2

Annual Usage (lbs) 4. Are any HAP-containing adhesivies utilized in repair of foam as part of the production process? No Adhesive is used in repair of foam for this process.