DAQE-AN0033007-04

November 15, 2004

Paul H. Griffin Owens Corning

PO Box 27397

4340 West 850 South Salt Lake City, Utah 84127

Dear Mr. Griffin:

Re: Approval Order: Replace Manual Lint Cleaning S ystem With a Mechanical System Salt Lake County – CDS SM; NA; MAINT; NSPS, HAPs, TITLE V Project Code: N0033-007

The attached document is an Approval Order for the above-referenced project.

Future correspondence on this Intent to Approve sho uld include the engineer's name as well as the DAQE number as shown on the upper right-hand corner of t his letter. Please direct any technical questions you may have on this project to Mr. Maung Maung. He ma y be reached at (801) 536-4153.

Sincerely,

Richard W. Sprott, Executive Secretary Utah Air Quality Board

RWS:MM:re

cc: Salt Lake Valley Health Department Mike Owens, EPA Region VIII

150 North 1950 West • PO Box 144820 • Salt Lake City, UT 84114-4820 • phone (801) 536-4000 • fax ( 801) 536-4099

T.D.D. (801) 536-4414 • www.deq.utah.gov 

## State of Utah

Department of Environmental Quality

Dianne R. Nielson, Ph.D.

Executive Director

DIVISION OF AIR QUALITY Richard W. Sprott

Director OLENE S. WALKER

Governor

GAYLE F. McKEACHNIE

Lieutenant Governor

## STATE OF UTAH

Department of Environmental Quality

Division of Air Quality

APPROVAL ORDER: Replace Manual Lint Cleaning Syste m

With a Mechanical System

Prepared By: Maung Maung, Engineer

(801) 536-4153 Email: mmaung@utah.gov



### APPROVAL ORDER NUMBER

DAQE-AN0033007-04

Date: November 15, 2004



## Owens Corning

Source Contact

Paul H. Griffin (801) 973-6375

Ext. 12

Richard W. Sprott Executive Secretary Utah Air Quality BoardAbstract

Owens Corning has requested modification of their c urrent Approval Order (AO) DAQE-AN0033008-02, dated September 20, 2002, to rep lace a lint screen on the Fiber/Pack Forming Section of the unbonded loose fill line with an aut omated screen cleaning system. Current system requires the filter cake to be manually removed fro m the lint screen quite frequently. Owens Corning proposes to install an automated screen cleaning me chanism which vacuums the captured lint off the collection system. This replacement of lint cleani ng system meets the requirements of R307-413-3, Flexibility changes.

The Owens Corning site is located in Salt Lake City , Utah. Salt Lake County is a non-attainment area of the National Ambient Air Quality Standards (NAAQ S) for PM 10 and SO 2

, and is a maintenance area for ozone. New Source Performance Standards (NSPS) , Subpart PPP, (Standards of Performance for Wool Fiberglass Insulation Manufacturing Plants) ap plies to this source. Title V of the 1990 Clean Air Act applies to this source and the Salt Lake Ci ty Owens Corning plant is a minor Title V source. There will be no increase in emissions from this ch ange.

The above-referenced project has been evaluated and found to be consistent with the requirements of th e Utah Administrative Code Rule 307 (UAC R307), and t he Utah Air Conservation Act. A public comment period was not required for this project. This air quality AO authorizes the project with the following conditions and failure to comply with any of the conditions may constitute a violation of th is

order.

General Conditions:

1. This AO applies to the following company:

Site Office Owens Corning

4340 West 850 South Salt Lake City, Utah 84104

Phone Number: (801) 973-6375 Fax Number: (801) 972-4576

The equipment listed in this AO shall be operated a t the following location:

PLANT LOCATION:

4340 West 850 South Salt Lake City, Utah

Universal Transverse Mercator (UTM) Coordinate Syst em: Datum NAD 27 4,511.45 kilometers Northing; 416.05 kilometers Eas ting; Zone 12

2. All definitions, terms, abbreviations, and referenc es used in this AO conform to those used in the Utah Administrative Code (UAC) Rule 307 (R307) and Title 40 of the Code of Federal Regulations (40 CFR). Unless noted othe rwise, references cited in these AO

conditions refer to those rules.

3. The limits set forth in this AO shall not be exceed ed without prior approval in accordance

with R307-401.DAQE-AN0033007-04

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4. Modifications to the equipment or processes approve d by this AO that could affect the

emissions covered by this AO must be reviewed and a pproved in accordance with

R307-401-1.

5. All records referenced in this AO or in applicable NSPS which are required to be kept by the owner/operator, shall be made available to the Executive Secretary or Executive Secretary’s representative upon request, and the re cords shall include the two-year period prior to the date of the request. Records shall be kept for the following minimum periods:

A. Emission inventories Five years from the due date o f each emission statement or until the next inventory is due, whichever is longer.

B. All other records Two years

6. Owens Corning, Inc. shall replace manually cleaned lint screen equipment with a automatic screen cleaning system and shall conduct its operations of the fiberglass insulation plant in accordance with the terms and c onditions of this AO, which was written pursuant to Owens Corning’s Notice of Inten t (NOI) submitted to the Division of Air Quality (DAQ) on September 14, 2004.

7. This AO shall replace the AO (DAQE-AN0033008-02) da ted September 20, 2002.

8. The approved installations shall consist of the fol lowing equipment or equivalent*:

A. Two Owens Corning PR1 fiberizers for the Batt line One Owens Corning RH15 fiberizer for the ProPink fi ll line

B. Glass raw material handling system consisting of :

Pneumatic conveying system to transport raw materia l from delivery trucks to storage bins

Seven enclosed storage bins, each with an individua l dust collector, Mikropul model 25S-8 C style with a total filter area of 242 sq. ft

Batch mixer/weighing with dedicated Mikropul model 25S-8C style dust

collector

The 8 dust collectors above, vent internally to the batch house

Miscellaneous enclosed transfer/feed system

C. Resin and binder handling system consisting of:

One urea storage silo with a bin vent filter

One urea solution mix tank Two resin pre-mix tanks

One binder mix tankDAQE-AN0033007-04

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One binder run tank

One resin bulk storage tank One binder oil bulk storage tank One mineral oil bulk storage tank

D. Two electric furnaces used to produce molten gla ss, each with a 49S-8-20 MikroPul pulse jet baghouse with 462 ft 2 of filter area

E. One batt insulation production line using the ro tary spin process with two associated fiberizers, conveyors, natural gas-fired curing oven and cooling table with the following stacks:

Stack 28: Emissions from the forming section and cu ring oven

Stack 65: Emissions from the cooling table with fil ter screen box with 5 ft 2

of filter area

F. One sock-type filter with 43 ft 2 of filter area on the exhaust of the receiver/bagge r unit on the batt line edge trim and scrap material blowing wool system.

G. One ProPink production line using the rotary spin p rocess with one associated fiberizer and penclone air filter with the followin g stack:

Stack 28: Emissions from the forming section

H. Unbonded loose fill line with forming exhaust lint screen.

* Equivalency shall be determined by the Executive Secretary.

Stack Parameters

9. Owens Corning’s Western Fiberglass Plant shall noti fy the Executive Secretary in writing

when the installation of the automated screen clean ing system listed in Condition # 8.H have been completed and are operational, as an init ial compliance inspection is required. To insure proper credit when notifying the Executiv e Secretary, send your correspondence to the Executive Secretary, attn: Co mpliance Section.

If construction and installation have not been comp leted within eighteen months from the date of this AO, the Executive Secretary shall be n otified in writing on the status of the construction and installation. At that time, the E xecutive Secretary shall require

documentation of the continuous construction and in stallation of the operation and may

revoke the AO in accordance with R307-401-11.

Limitations and Tests Procedures

10. Emissions to the atmosphere at all times from t he indicated emission points shall not exceed the following rates and concentrations:DAQE-AN0033007-04

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Source: Batt insulation line (Stack 28 and Stack 6 5 combined)

Pollutant lb/ton glass pulled

TSP ................................................ ..............................9.00

PM 10

................................................... ..........................9.00

Source: ProPink line (Stack 28)

Pollutant lb/ton glass pulled

PM 10

................................................... ....................... 5.00

11. Stack testing to show compliance with the emiss ion limitations stated in the above condition shall be performed as specified below:

A. Testing Emission point

Pollutant Frequency

Batt insulation line TSP........................... . * (Stack #28 & 65) PM 10 ........................... *

ProPink unbonded loose fill line (Stack #28) PM 10 ........................... *

B. Testing Status (To be applied above)

* Test every five years. The Executive Secretary m ay require testing at any time.

C. Notification

The Executive Secretary shall be notified at least 30 days prior to conducting any required emission testing. A source test protocol shall be submitted to DAQ when the testing notification is submitted to the E xecutive Secretary.

The source test protocol shall be approved by the E xecutive Secretary prior to performing the test(s). The source test protocol s hall outline the proposed test methodologies, stack to be tested and procedures to be used. A pretest conference shall be held, if directed by the Execut ive Secretary.

D. Sample Location

The emission point shall be designed to conform to the requirements of 40 CFR 60, Appendix A, Method 1, or other methods as appro ved by the Executive Secretary. An Occupational Safety and Health Admin istration (OSHA) or Mine Safety and Health Administration (MSHA) approved ac cess shall be provided to

the test location and the test site.DAQE-AN0033007-04

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E. Volumetric Flow Rate

40 CFR 60, Appendix A, Method 2

F. PM 1 0 Stack Testing Methods

40 CFR 60, Appendix A, Method 5, 5a, 5d, or 5e as a ppropriate and 40 CFR 51, Appendix M, Method 202.

Method 5 and 202 consists of the addition of filter able particulate and the condensable content in the impi ngers (organics and inorganic).



### G. Calculations

To determine the mass emission rates (lb/ton, etc.) the pollutant concentration as determined by the appropriate methods shall be mult iplied by the volumetric flow rate and any necessary conversion factors dete rmined by the Executive Secretary to give the results in the specified unit s of the emission limitation.



### H. New Source Operation

For a new source/emission point, the production rat e during all compliance testing shall be no less than 90% of the production rate listed in this AO. If the maximum AO allowable production rate has not been a chieved at the time of the test, the following procedure shall be followed:

1) Testing shall be at no less than 90% of the product ion rate achieved to

date.

2) If the test is passed, the new maximum allowable pr oduction rate shall be 110% of the tested achieved rate, but not more than the maximum allowable production rate. This new allowable maxi mum production rate shall remain in effect until successfully tested at a higher rate.

3) The owner/operator shall request a higher productio n rate when necessary. Testing at no less than 90% of the high er rate shall be conducted. A new maximum production rate (110% of the new rate) will then be allowed if the test is successful. This pr ocess may be repeated until the maximum AO production rate is achieved.



### I. Existing Source Operation

For an existing source/emission point, the producti on rate during all compliance testing shall be no less than 90% of the maximum pr oduction achieved in the previous three (3) years.

12. Urea and resin mixture shall be held minimum of two hours before adding it to the binder

mix.DAQE-AN0033007-04

Page 

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13. Free formaldehyde concentration of the resin in the pre-mix tank actively in use for

binder mixing shall not exceed 1%.

14. Visible emissions from any stationary point or fugi tive emission source associated with

the source or with the control facilities shall not exceed 10% opacity for fabric filters exhaust stacks and 20% for all others. Opacity obs ervations of emissions from stationary sources that exhaust to the atmosphere s hall be conducted in accordance with 40 CFR 60, Appendix A, Method 9.

15. The consumption limit of 1.80 tons of glass melted per hour, averaged over a 12-hour period shall not be exceeded. To determine complia nce with a rolling 12-month total the owner/operator shall calculate a new 12-month total by the twentieth day of each month using data from the previous 12 months. Records of consumption shall be kept for all periods when the plant is in operation. Consumptio n shall be determined by production records. The records of consumption shall be kept on a daily basis.

Fuels

16. The owner/operator shall use only natural gas a s a primary fuel.

Federal Limitations and Requirements

17. In addition to the requirements of this AO, all provisions of 40 CFR 60, New Source Performance Standards (NSPS) Subparts A and PPP, 40 CFR 60.1 to 60.18 and 40 CFR 60.680 to 60.685 (Standards of Performance for Wool Fiberglass Insulation Manufacturing Plants) apply to this installation.

Volatile Organic Compound (VOC) and Hazardous Air P ollutants (HAPs) Limitations

18. The plant-wide emissions of VOCs and HAPs from plant production operations shall not exceed:

10.04 tons per rolling 12-month period for VOCs 0.01 tons per rolling 12-month period for Acetaldeh yde 8.92 tons per rolling 12-month period for formaldeh yde 9.71 tons per rolling 12-month period for methanol 5.41 tons per rolling 12-month period for phenol 0.22 tons per rolling 12-month period for acid gase s* 0.30 tons per rolling 12-month period for solid HAP s** 24.57 tons per rolling 12-month period for all HAPs combined

*Acid gases includes hydrogen fluoride and hydrogen chloride

**Solid HAP include antimony, arsenic, beryllium, c admium, chromium, cobalt, lead, phosphorus, manganese, and nickel

Compliance with each/the limitation shall be determ ined on a rolling 12-month total. Based on the twentieth day of each month, a new 12- month total shall be calculated using data from the previous 12 months.DAQE-AN0033007-04

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The plant-wide emissions of VOC and HAP emitted to the atmosphere shall be

determined by maintaining a record of VOC potential and HAP potential contained in

materials used each month. The record shall includ e the following data for each item

used:

A. Name of the VOC and HAP emitting material, such as: binder, batch, glass pull, finished product, etc.

B. The unit ratio of each VOC and HAP emitting materia l per unit of product

manufactured.

C. The amount of product manufactured on a monthly bas is.

D. Amount and location of materials containing VOC and HAP used on a monthly basis and summed for every location and for the ent ire plant each month.

E. To calculate the above emissions based on product w eight manufactured by using the general procedure below:

VOC (tons) = Unit Ratio of Product (lb VOC) x tons of production x 1 ton ton production 2000 lbs

HAP (tons) = Unit Ratio of Product (lb HAP) x tons of production x 1 ton ton production 2000 lbs

F. Records of consumption of VOC and HAP shall be kept for all periods when the plant is in operation.

Records & Miscellaneous

19. Records of hold-time for urea-resin mixture for each mix before adding to the binder mix

shall be maintained.

20. Owens Corning’s Salt Lake City Plant shall test free formaldehyde concentration in the resin pre-mix tank at least once every calendar mon th. Records of free formaldehyde concentration in the resin pre-mix tank for each ba tch of mix tested shall be maintained.

21. At all times, including periods of startup, shutdow n, and malfunction, owners and operators shall, to the extent practicable, maintai n and operate any equipment approved under this AO including associated air pollution co ntrol equipment in a manner consistent with good air pollution control practice for minimi zing emissions. Determination of whether acceptable operating and maintenance proced ures are being used will be based on information available to the Executive Secretary wh ich may include, but is not limited to, monitoring results, opacity observations, review of operating and maintenance procedures, and inspection of the source. All main tenance performed on equipment authorized by this AO shall be recorded.

22. The owner/operator shall comply with R307-150 Serie s. Inventories, Testing and Monitoring.DAQE-AN0033007-04

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23. The owner/operator shall comply with R307-107. Gen eral Requirements: Unavoidable

Breakdowns.

The Executive Secretary shall be notified in writin g if the company is sold or changes its name.

This AO in no way releases the owner or operator fr om any liability for compliance with all other applicable federal, state, and local regulations in cluding R307.

A copy of the rules, regulations and/or attachments addressed in this AO may be obtained by contacting the Division of Air Quality (DAQ). The Utah Admini strative Code R307 rules used by DAQ, the NOI guide, and other air quality documents and forms ma y also be obtained on the Internet at the following

web site: http://www.deq.state.ut.us/eqair/aq_home.htm

The annual emission estimations below include point source and fugitive emissions, and do not include fugitive dust, road dust, tail pipe emissions and g randfathered emissions. These emissions are for th e purpose of determining the applicability of Prevent ion of Significant Deterioration, non-attainment ar ea, maintenance area, and Title V source requirements o f the R307. They are not to be used for determinin g compliance

.

The Potential To Emit (PTE) emissions for the Owens Corning plant are currently calculated at the following values:

Pollutant Tons/yr

A. PM 10

................................................... ..............69.93

B. SO 2

................................................... ................. 8.22

C. NO

x ................................................... ...............17.62

D. CO................................................. ...................42.37

E. VOC (excluding HAPs)............................... ....10.04

F. Ammonia ............................................ .............30.94

G. HAPs

Acetaldehyde..................................0.01 formaldehyde..................................8.92

methanol.........................................9. 71 phenol............................................. 5.41 acid gases*......................................0. 22

solid HAPs**..................................0.30

Total HAPs ........................................ .............24.57

* Acid gases includes hydrogen fluoride and hydro gen chloride

** Solid HAPs include antimony, arsenic, beryllium, cadmium, chromium, cobalt, lead, phosphorus, manganese, and nickel

Approved By:

Richard W. Sprott, Executive Secretary Utah Air Quality Board