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ENCLOSURE 1 

INFORMATION COLLECTION REQUEST FOR 

Flexible Polyurethane Foam Production 

We are conducting this Information Collection Request (ICR) to assist the EPA 

Administrator in developing emission standards for Flexible Polyurethane Foam 

under Clean Air Act (CAA) section 112. We are sending this ICR to you under the 

authority of Section 114 of the CAA. 

BACKGROUND: 

We are required by section 112(f)(2) of the Clean Air Act (CAA) to assess the risk 

remaining (residual risk) eight years after the application of maximum achievable 

control technology (MACT) standards under section 112(d). If we find the residual 

risk fails to protect public health with an ample margin of safety or to prevent 

(taking into consideration various factors) adverse environmental effects, we are 

required to promulgate more stringent standards. The Flexible Polyurethane Foam 

MACT standard was promulgated in October 1998 (see 63 FR 53980). We are 

preparing to initiate our residual risk review. Please note this survey is for flexible 

polyurethane foam production only and does not cover flexible polyurethane foam 

fabrication, other than identifying if flexible polyurethane foam fabrication is 

conducted as a co-located operation. 

Section 114(a) of the CAA gives us the authority to require you to provide us with 

information for the following purposes: 

1. Developing or assisting in the development of the following:

a. State implementation plans (§§ 110 and 111(d)); 

b. New Source Performance Standards (NSPS) (§ 111); 

c. National Emissions Standards for Hazardous Air Pollutants (NESHAP) 

(§ 112); 

d. Solid waste combustion or other related solid waste regulations (§ 129); 

2. Determining whether any person is in violation of any standards or 

requirements developed under the authorities cited above; or 

3. Carrying out any provision under the CAA (except certain provisions under 

Title II). 
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The Administrator may require that those persons identified above do the 

following so the Administrator may have the information necessary for the items 

listed in #1-3: 

 make reports; 

 establish and maintain records; 

 install, use, and maintain monitoring equipment, and use audit procedures, or 

methods; 

 sample emissions (in accordance with such procedures or methods, at such 

locations, at such intervals, during such periods, and in such manner as we 

shall prescribe); 

 keep records on control equipment parameters, production variables or other 

indirect data when direct monitoring of emissions is impractical; 

 submit compliance certifications in accordance with section 114(a)(3); and 

 provide such other information as we may reasonably require. 

We seek information on existing flexible polyurethane foam production sources in 

this survey in order to collect information needed to conduct the residual risk review 

required by section 112 of the Act. 

DIRECTIONS FOR COMPLETING THIS SURVEY: 

You must complete and return this survey by December 6, 2011. You must 

identify clearly any response(s) that you consider to be confidential business 

information (CBI). Any responses not so identified will be included in a publicly 

available database. You may refer to Enclosures , 3, 4, 5, and 6 to learn how we will 

treat CBI as well as what information you may be asked to submit later to 

substantiate a claim of confidentiality. 

DEFINITIONS: For the purposes of this ICR only, use the following definitions: 

Auxiliary blowing agent, or ABA, means a low-boiling point liquid added to assist 

foaming by generating gas beyond that resulting from the isocyanate-water reaction. 

Flexible polyurethane foam means a flexible cellular polymer containing urea and 

carbamate linkages in the chain backbone produced by reacting a diisocyanate, 

polyol, and water. Flexible polyurethane foams are open-celled, permit the passage 

of air through the foam, and possess the strength and flexibility to allow repeated 

distortion or compression under stress with essentially complete recovery upon 

removal of the stress. 

Flexible polyurethane foam process means the equipment used to produce a flexible 

polyurethane foam product. For the purpose of this survey, the flexible polyurethane 
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foam process includes raw material storage; production equipment and associated 

piping, ductwork, etc.; and curing and storage areas. 

HAP ABA means methylene chloride, or any other HAP compound used as an 

auxiliary blowing agent. 

Initial startup means the first time a new or reconstructed affected source begins 

production of flexible polyurethane foam. 

Rebond foam means the foam resulting from a process of adhering small particles of 

foam (usually scrap or recycled foam) together to make a usable cushioning product. 

Various adhesives and bonding processes are used. A typical application for rebond 

foam is for carpet underlay. 

Rebond foam process means the equipment used to produce a rebond foam product. 

For the purpose of this subpart, the rebond foam process includes raw material 

storage; production equipment and associated piping, ductwork, etc.; and curing and 

storage areas. 

Recovery device means an individual unit of equipment capable of and used for the 

purpose of recovering chemicals for use, reuse, or sale. Recovery devices include, 

but are not limited to, carbon adsorbers, absorbers, and condensers. 

Slabstock flexible polyurethane foam means flexible polyurethane foam that is 

produced in large continuous buns that are then cut into the desired size and shape. 

Slabstock flexible polyurethane foam production line includes all portions of the 

flexible polyurethane foam process from the mixhead to the point in the process 

where the foam is completely cured. 

Storage vessel means a tank or other vessel that is used to store diisocyanate or HAP 

ABA for use in the production of flexible polyurethane foam. Storage vessels do not 

include vessels with capacities smaller than 38 cubic meters (or 10,000 gallons). 

CONFIDENTIAL BUSINESS INFORMATION (CBI): 

Please indicate if any CBI is included in this survey response: Y N 
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Flexible Polyurethane Foam Production Survey Form

PART I. OWNER INFORMATION

For questions 3 through 5, provide a separate Part I form for each facility, if 

you own or operate more than one facility.

1. Name of Legal Owner: Hickory Springs Manufacturing Company 

 a. Address: 235 2nd Avenue NW 

 b. City: Hickory 

 c. State: North Carolina 

 d. Zip: 28601 

 e. County: Catawba 

2. Facility Name: Conover Complex 

3. Complete street address of facility (physical location):

 a. Address: 1115 Farrington Street 

 b. City: Conover 

 c. State: North Carolina 

 d. Zip: 28613 

 e. County: Catawba 

 f. Longitude and Latitude coordinates [in decimal degrees with five significant 

figures to the right of the decimal place (e.g., 38.27941, -85.64371)]: 

 35.717470, -81.241851 

4. Facility Contact:

 a. Name (First Name, Last Name): Stephen Aldridge

 b. Title: Environmental Manager 

 c. Telephone Number: (828) 328-2201 Ext 4811 

 d. Fax Number: ( ) 

 e. E-mail address: smaldridge@hickorysprings.com 

 f. Primary NAICS code for the facility: 32615 
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5. Flexible Polyurethane Foam Production 

 We believe that you own or operate a facility that engages in production of 

slabstock, molded or rebond flexible polyurethane foam. If you believe that this 

survey does not pertain to you, please indicate your reason below: 

Plant is permanently shut down. Please also identify the date the Foam 

Production plant was shut down and what steps were taken to close the Foam 

Production plant. Include date the permit was inactivated. 

 ________________________________________________________________

 ________________________________________________________________

________________________________________________________________

No slabstock, rebond, or molded flexible polyurethane foam production plant 

is located at this facility.

If you do not operate a flexible polyurethane foam production plant (i.e., you 

check either box for question 5), we will review that information and respond 

as to whether you need to complete any other part of the survey 

Please mail, fax, or e-mail Part I to: 

U.S. EPA Mailroom 

 Attn: Sharon Nizich 

 Mail Code: D243-04 

 Research Triangle Park, NC 27711 

 Phone: 919 541 2825 

 Fax: 919 541-5450 

 Email address: Nizich.sharon@epa.gov
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PART II. GENERAL FACILITY INFORMATION 

1. Please provide the following general information for each flexible 

polyurethane foam production plant: 

 a. Number of employees at the facility where the flexible polyurethane foam 

production is located: 175 (Foam pouring, R&D and foam fabrication)

b. Number of employees at the parent company, organization or institution (e.g. 

municipality, university, etc.) that owns the facility: 2,511 (company-wide)

c. Is the legal owner a small entity as defined by the Regulatory Flexibility Act? 

 Refer to the Small Business Administration’s Size Standards at: 

 http://www.sba.gov/sites/default/files/Size_Standards_Table.pdf 

 Y  N Unknown 

 [insert the following if applicable] 

d. Any other co-located operations and if so, what type of operation? 

Polyurethane Foam Fabrication, Wire Drawing, and a Polyethylene Foam 

Extrusion Operation 

e. Are any operations on site subject to federal and State emission standards and 

if yes, which standards? 
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f. Is the facility a major source or area source? Major sources are all activities 

located on contiguous area under common control where the aggregate potential to emit for the 

activities exceeds ten (10) tons per year of a single HAP or twenty-five (25) tons per year of a 

combination of HAPs. Yes

g. Type of plant. Check all that apply. 

Molded Flexible Polyurethane Foam 

 Slabstock Flexible Polyurethane Foam 

Rebond Foam Production 

h. Please list information concerning storage tanks at this facility, including size, 

contents, estimated emissions of emitted pollutants, and piping characteristics. 

Utilize a flow diagram if necessary. 

 See ATTACHMENT A. 

2. Please provide a flow diagram of the process units associated with the 

flexible polyurethane foam production process at your facility. Label each 

process unit and emission point with a unique identification code and 

complete the table below. 

 The flow diagram should display an identification code for streams entering 

(raw materials/feedstocks) and exiting the process unit (product streams), 

and emission streams. The flow diagram should also display an identification 

code for add-on control devices and streams entering and exiting the add-on 

control devices. Where applicable, include in-process streams, waste 

streams, wastewater streams, and emission release points in the flow 

diagram. 

Identification code Description of item submitted with survey response 

I-01-1 through I-01-13 Raw materials associated with flexible polyurethane foam 

manufacturing. Tank details are provided in Attachment A.

I-01-1, I-02-1, I-03-1, 

I-04-1, I-05-1, I-06-1, 

1-07-1 

Storage Vessels containing Toluene Diisocyanate (CAS# 

264-71-625) and Methylene Diphenyl Diisocyanate (CASs 

101-68-8, 26447-40-5) 

EP-F-01 through 

EP-F-06 

Emissions associated with flexible polyurethane foam 

manufacturing process. 

ES-F-01(j) Emissions associated with curing and temporary storage of 

flexible polyurethane foam. 

ES-F-01(k).1 and .2 Emissions associated with the rapid curing (“Bun-Gas 

Extraction”) system. 
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ES-F-02 Emissions associated with the fabrication operations 

associated with flexible polyurethane foam. 

PS-001 Final bedding or furniture component products for delivery 

to customers. 

 

 

 

 

3. List Federal air pollution control regulations applicable to each process unit. 

Process unit name

Process unit 

identification code 

Federal air pollution control 

regulation 

PU Foam Mfg ES-F-01 40 CFR Part 63, Subpart III 

PU Foam Mfg I-01-1, I-02-1, I-03-1, 

I-04-1, I-05-1, I-06-1, 

1-07-1 

40 CFR Part 63, Subpart III 

PU Foam Mfg ES-F-01 40 CFR 63.11416(b) 

PU Foam Fab ES-F-02 40 CFR 63.11416(e) 
Enclosure 2

Location:

2010 2009 2008 2010 2009

PU Foam Mfg ES-F-01 305,730,664 265,229,713 312,166,278 Board Feet 240 hrs 240 hrs

 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 name

Hickory Springs Manufacturing Company, Conover, NC
Enclosure 2

2008

240 hrs

 time each product was 

ured (e.g., days, or hours)
Enclosure 2

2010 2009 2008

PU Foam Mfg TDI mi Pounds 13,663,385 12,071,074 14,279,947

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/feedstock
Enclosure 2

Raw material 

products/feedstock

Auxiliary Blowing 

Agents Chemical Compounds

% of each chemical 

compound

2,4-TDI 80%

2,6-TDI 20%

Acetone Acetone Acetone 100%

Carbon Dioxide CO2 CO2 100%

Polyols - - Polyether poyol 100%

Surfactant - - Silicone 100%

Catalyst - - Amine catalyst 100%

Colorant - - Dyes 100%

3. Provide composition information for feedstock/raw materials.

Toluene Diisocyanate (mi) - -
Adhesive Name HAP Contained HAP Content (wt%)

4. Are any HAP-containing adhesivies utilized in repair of foam as part of the production process?

None Used
Enclosure 2

Annual Usage (lbs)

process?
Xylenes (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 & Compounds

Hexane

Formaldehyde

p-Xylene

Acetaldehyde

Acrylonitrile

Ethylene Glycol
Enclosure 2a

Hours

Per (e.g., week, 

month, year)

ES-F-01 1977 Not available 25 years Not available 30 week

Owner Name: _Hickory Springs Manufacturing Company________________________________ Facility Name: __Conover Complex_________________________

 Process Unit ID: _ES-F-01________________________________________

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 unit
Enclosure 2a

Owner Name: _________________________________________ Facility Name: ______________________________

 Process Unit ID: _____________________________

ES-F-01 No air pollution control devices

 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 

Process unit ID made

Year(s) upgrade was 

made
Enclosure 2a

Process Unit ID

Total operating and 

maintenance costs 2008 2009 2010

ES-F-01

Owner Name: _____________________ Facility Name: _______________________________________

 Process Unit ID: ____________________________________

No Air Pollution Control Devices

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#cccinfo
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

Tons per year 

2009

EP-F-01 ES-F-01 2,4-Toluene Diisocyanate

EP-F-02 ES-F-01 2,4-Toluene Diisocyanate

EP-F-03 ES-F-01 2,4-Toluene Diisocyanate

EP-F-04 ES-F-01 2,4-Toluene Diisocyanate

EP-F-05 ES-F-01 2,4-Toluene Diisocyanate

EP-F-06 ES-F-01 2,4-Toluene Diisocyanate

ES-F01(j) ES-F-01 2,4-Toluene Diisocyanate

ES-F01(k).1 ES-F-01 2,4-Toluene Diisocyanate

ES-F01(k).2 ES-F-01 2,4-Toluene Diisocyanate

0.24* 0.17* 0.23* 0.19*

 unit.

Owner Name: __________________________________________ Facility Name: ____________________________

 Process Unit ID: ___________________________

 Include storage tanks or any auxiliary equipment on site, per unit ID and label each as type of
* Emissions are for TDI Mixed Isomers (2,4 and 2,6-TDI).
Enclosure 2a

Tons per year 

2010

0.21*

____________________
Enclosure 2a

Owner Name: __________________________________________ Facility Name: ____________________________

 Process Unit ID: ___________________________

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 emissions testing perfomed at facility.

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.

b. Describe emission release point(s) that were tested: __________________________________________________

c. Date of test: ______________________________________

d. Specify the test method(s) used: ___________________________________________________________________

 _________________________________________________________________________________________________

e. Submit a copy of the test reports.
Enclosure 2a

Owner Name: ______________________________ Facility Name: ____________________________

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

b. Does the process unit have a control device that reduces air pollution : _____ Yes _____ No

c. Describe the release point(s) that are being controlled (e.g., equipment or unit operation 

 where the release point is located): __________________________________________________

 __________________________________________________________________________________

 __________________________________________________________________________________

 __________________________________________________________________________________

 Process Unit ID: ___________________________

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

 ___________________________________________________________________________________

 ___________________________________________________________________________________

 following information for each unit: 

f. Manufacturer: _____________________________________________________________________

a. Process Unit ID: _____________________________________________________________________

There are no air pollution control devices at the facility.

i. List the elements that are included in the installed cost estimate in question IV.5.h 

 __________________________________________________________________________________

g. Model No: ________________________________________________________________________

e. Year installed: _____________________________________________________________________

h. Original installed cost of the control device (capital cost of the control plus installation cost): 

d. Type of control device: _____________________________________________________________

 ___________________________________________________________________________________

 __________________________________________________________________________________
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 each 
Enclosure 2a

Process unit ID

Measures or modification made to 

minimuze emissions

Estimated emission 

reduction (lb/yr)

ES-F-01

Maintenance procedures for pumps, 

hoses, pipelines Unknown

Owner Name: _______________________________ Facility Name: ________________________

 Process Unit ID: _______________________

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:
Enclosure 2a

No emission reduction techniques have been performed at the facility.

Emission reduction technique 

descriptions Pollutants affected Reduction efficiency

________________________ _______________________ ____________________

________________________ _______________________ ____________________

________________________ _______________________ ____________________

________________________ _______________________ ____________________

________________________ _______________________ ____________________

________________________ _______________________ ____________________

Owner Name: __________________________________________ Facility Name: ____________________________

______________________________________________________________________________________________

c. At what frequency is parameter monitoring done? ______________________________________________

d. Describe initial and ongoing parameter monitoring quality assurance/control: 

6. Other emission reduction techniques. Include any information about changes made in raw material usage to

 Process Unit ID: ___________________________

 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?

 ___________________________________________________________________________________________

 ___________________________________________________________________________________________

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.

 ___________________________________________________________________________________________

 ___________________________________________________________________________________________

f. What is annual parameter monitoring cost?

 ___________________________________________________________________________________________

e. At what frequency is parameter monitor quality assurance/control (e.g., calibration) performed?
Enclosure 2a

Other than normal day-to-day start up and shutdown cycles, no emergency shutdown/start-up events have occurred during the past 3 years.

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)

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.

Owner Name: __________________________________________ Facility Name: ____________________________

 Process Unit ID: ___________________________

8. Please provide the following information for each process unit during start-up and shutdown operation:
No existing procedures are utlized or followed to minimize emissions during normal start-up

and shutdown activities.

 _______________________________________________________________________________

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 _____No

e. If the answer to Part IV 9.d. is yes, please explain, in detail, how and why emissions are different 

__________________________________________________________________________________

__________________________________________________________________________________

f. Do you have test data that show emissions durint start-up or shutdown? __ Yes _X_ No

 _______________________________________________________________________________

h. Please identify the emissions test method(s) used during start-up or shutdown.

 _______________________________________________________________________________

 _______________________________________________________________________________

g. If yes, when and why did you conduct such testing? __________________________________

Owner Name: ___________________________ Facility Name: ____________________________

 Process Unit ID: ___________________________

 _______________________________________________________________________________

 (either stand-alone or contrained within the periodic excess emissions report) to your

 permitting aurhority? ___No_________________________________________________________

 _______________________________________________________________________________

i. What were the test conditions at the time of testing ? ________________________________

 _______________________________________________________________________________

 _______________________________________________________________________________

 of the flexible polyuretuane foam production process unit.

k. Are you required to submit periodic and immediate start-up and shutdown reports

 _______________________________________________________________________________

j. Please submit a copy of any test data you have conducted during any start-up or shutdown
Enclosure 2a

Longitude Latitude

EP-F-01 ES-F-01 95 27.6 77 3.5

EP-F-02 ES-F-01 95 27.6 77 3.5

EP-F-03 ES-F-01 95 27.6 77 3.5

EP-F-04 ES-F-01 95 27.6 77 3.5

EP-F-05 ES-F-01 50 61.2 75 2.5

EP-F-06 ES-F-01 50 61.2 75 2.5

Owner Name: ___________________________ Facility Name: ____________________________

 Process Unit ID: ___________________________

9. Stack Relase Parameters for Emission Points

 Please provide the following information for all emission release points for use in righ modeling

Diameter of 

release point 

(feet)

Location of release point (decimal 

degrees, minimum 5 digits beyond 

Emission decimal)

Point Process Unit ID

Height of 

release point 

(feet)

Exit of velocity 

of vent release 

point 

(feet/second)

Exit 

temperature of 

vent/flue gas 

(F)
Height of 

release point Release Height

Longitude Latitude (ft) (ft)

Not Currently Available

 apply. Notes on modeling data definitions are below.

Owner Name: ___________________________ Facility Name: ____________________________

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

Location of release point 

(decimal degrees, 

minimum 5 digits beyond 

Emission decimal)

Point

Process Unit 

ID

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.
Angle 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)

ilable

_

Dimension of Source
Enclosure 2a

b. Please list the pollutants that the scrubber is intended to reduce or remove.

Owner Name: ___________________________ Facility Name: ____________________________

 Process Unit ID: ___________________________

11. Scrubber

a. Does the flexible polyurethane foam production process unit have a scurbber? 

_____ Yes ___X__ No

k. Mist eliminator: _____ Yes _____ No

 _______________________________________________________________________________

 _______________________________________________________________________________

c. Type of scrubber: _______________________________________________________________

d. Design pollutant-laden gas inlet flow rate: ______acfm

e. Design pollutant-laden gas inlet temperature: ________oF

f. Scrubbing medium (describe): ____________________________________________________

g. Influent scrubbing medium pH: ___________________________________________________

h. Effluent scurbbing medium pH: ___________________________________________________

i. Scrubber water flow: _________________________________________________ gals/min (?)

j. Scrubber pressure drop (across each scrubber--provide units): _________________________

 _______________________________________________________________________________

n. What control devices are upstream of the scrubber? _________________________________

o. What control devices are downstream of the scrubber? ______________________________

l. Average outlet gas temperature for each scurbber: ________________________________oF

m. Please describe the source and quality of the water fed to the scrubber (e.g., effluent 

 water with a total solids content of _____): _________________________________________

 _______________________________________________________________________________

 _______________________________________________________________________________

 _______________________________________________________________________________
Enclosure 2a

 Process Unit ID: ___________________________

No Carbon Adsorbers at the facility.

Legal Owner Name:

Facility Name:

Process Unit ID:

Process Unit ID for controlled processes:

Stack or Vent Height (ft)

Stack or Vent Diameter (ft)

Manufacturer/Model

Original Installation Date

Gas flow rate to condenser (acfm)

Inlet gas temerature (oF)

Compound Name

Volume Fraction

Compound Name

Volume Fraction

Compound Name

Volume Fraction

Compound Name

Volume Fraction

Organic compounds in inlet gas stream

Describe any plans to replace or upgrade the adsorber

Vendor guarantee on adsorber efficient (attach copy)

Describe preventative maintenance procedures and frequency

List all monitoring methods used, including parameters and frequency

CARBON ADSORBER

Owner Name: ___________________________ Facility Name: ____________________________

12. Carbon Adsorber

 Please include a copy of this table for each carbon adsorber controlling emissions from 

 flexible polyurethane foam production process unit.
Polyol

TDI or MDI*

Water

* Toluene diisocyanate, mixed isomers (CAS# 264-71-625), Emission Source ID No.s: I-01-1, I-04-1, I-05-1, I-06-1, 1-07-1.

Methylene diphenyl diisocyanate, mixed isomers (CAS#s 101-68-8 and 26447-40-5), Emission Source ID No.s: I-02-1 and I-03-1. 

TDI and MDI tank vents are either equipped with vapor recovery or carbon absorbers are installed. Transfer pumps are either sealess or are submerged in neutral oil.

** Acetone or liquid CO2 (no other blowing agent used)

1 There are no emission control devices associated with the emissions.

Blowing Agent**

SurfactantCatalystsColorant

Flow Control System

Bun Cut-Off Saw

Foaming Tunnel (VARIMAX) Tran

Conveyor

Mixing 

Head

Bottom Paper 

Wrap Take-Up

Side Plastic 

Take-Up

Bun Processing: Trimming, 

Slitting and Adhesive 

Operations 

(ES-F-02, MACT OOOOOO)

Traversing Hood 

Over Tunnel

Exhausts to Atmosphere1

(EP-F-01 to EP-F-06)

Location: Hickory Springs Manufacturing Company

Conover Complex, Conover, North CarolinaFlexible Polyurethane Foam Manufacturing [ES-F-01(a)]

Emission Source ID No. ES-F-01(a)

Bun 

Te

Exha

Ex

Exha

ES

Looper Machine 

Adhesive Operations 

(I-12, MACT OOOOOO)

Customers

Product Stream (PS -001)

OR

Emission Units 

I-01-1 through I-01-13

Emission Unit ES-F-02 
Bulk Storage Tanks

Facility: Conover, NC

Max. Date Const. O-Fill Containment

Chemical TK # Position Capacity Installed Type Dim'sions Location Protection Sheltered Features

TDI 1 H 25,000 1972 Steel 10 x 36 TDI House Yes Yes Concrete Block

4 H 20,000 1980 Steel 10.5 x 31 Tank Room Yes Yes Concrete Block

5 H 20,000 1980 Steel 10.5 x 31 Tank Room Yes Yes Concrete Block

6 H 20,000 1980 Steel 10.5 x 31 Tank Room Yes Yes Concrete Block

7 H 10,000 1983 Steel 10.5 x 15.5 Run Room Yes Yes Concrete Block

MDI

2 H 25,000 1972 Steel 10 x 36 TDI House Yes Yes Concrete Block

3 H 20,000 1980 Steel 10.5 x 31 Tank Room Yes Yes Concrete Block

Polyol 1 H 25,000 1972 Steel 10 x 36 OS TK Farm Yes No Concrete Block

2 H 25,000 1972 Steel 10 x 36 OS TK Farm Yes No Concrete Block

3 H 25,000 1972 Steel 10 x 36 OS TK Farm Yes No Concrete Block

4 H 25,000 1972 Steel 10 x 36 OS TK Farm Yes No Concrete Block

5 H 25,000 1972 Steel 10 x 36 OS TK Farm Yes No Concrete Block

6 H 25,000 1972 Steel 10 x 36 OS TK Farm Yes No Concrete Block

14 H 25,000 1972 Steel 10 x 36 OS TK Farm Yes No Concrete Block

7 H 20,000 90-94 Steel 10.5 x 31 OS TK Farm Yes No Concrete Block

8 H 20,000 90-94 Steel 10.5 x 31 OS TK Farm Yes No Concrete Block

9 H 20,000 90-94 Steel 10.5 x 31 OS TK Farm Yes No Concrete Block

10 H 20,000 90-94 Steel 10.5 x 31 OS TK Farm Yes No Concrete Block

11 H 20,000 1985 Steel 10.5 x 31 OS TK Farm Yes No Concrete Block

12 H 20,000 1987 Steel 10.5 x 31 OS TK Farm Yes No Concrete Block

13 H 20,000 1978 Steel 10.5 x 31 OS TK Farm Yes No Concrete Block

15 H 20,000 1981 Steel 10.5 x 31 Tank Room Yes Yes Concrete Block

16 H 20,000 1981 Steel 10.5 x 31 Tank Room Yes Yes Concrete Block

17 H 20,000 1981 Steel 10.5 x 31 Tank Room Yes Yes Concrete Block

18 H 20,000 1981 Steel 10.5 x 31 Tank Room Yes Yes Concrete Block

Polyol 19 H 20,000 1981 Steel 10.5 x 31 Tank Room Yes Yes Concrete Block

20 H 20,000 1981 Steel 10.5 x 31 Tank Room Yes Yes Concrete Block

21 H 20,000 1978 Steel 10.5 x 31 Lower TK R Yes Yes Concrete Block

22 H 10,000 1978 Steel 8 x 26.5 Lower TK R Yes Yes Concrete Block

23 H 10,000 1978 Steel 8 x 26.5 Lower TK R Yes Yes Concrete Block

24 H 10,000 1978 Steel 8 x 26.5 Lower TK R Yes Yes Concrete Block

41 H 10,000 1983 Steel 10.5 x 15.5 Run Room Yes Yes Concrete Block

42 H 10,000 1983 Steel 10.5 x 15.5 Run Room Yes Yes Concrete Block

43 H 10,000 1983 Steel 10.5 x 15.5 Run Room Yes Yes Concrete Block

1 H 6,000 1971 Steel 8 x 16 TDI House Yes Yes Concrete Block

2 H 6,000 1971 Steel 8 x 16 TDI House Yes Yes Concrete Block

3 H 6,000 1971 Steel 8 x 16 TDI House Yes Yes Concrete Block

4 H 6,000 1971 Steel 8 x 16 TDI House Yes Yes Concrete Block

25 V 5,000 1970 Steel 6 x 24 Lower TK R Yes Yes Concrete Block

26 V 5,000 1963 Steel 9 x 11 Lower TK R Yes Yes Concrete Block

27 V 5,000 1963 Steel 9 x 11 Lower TK R Yes Yes Concrete Block

35 V 5,000 1970 Steel 8 x 13.5 PIPA Room Yes Yes Concrete Block

36 V 5,000 1970 Steel 8 x 13.5 PIPA Room Yes Yes Concrete Block

37 H 3,000 1983 Steel 5.5 x 18 PIPA Room Yes Yes Concrete Block

38 H 3,000 1983 Steel 5.5 x 18 PIPA Room Yes Yes Concrete Block

39 H 3,000 ?? Steel Run Room Yes Yes Concrete Block

Acetone 1 H 8,000 Mid 90s Steel OS TK Farm Yes No Concrete Block

2 H 5,000 1969 Steel OS TK Farm Yes No Concrete Block

3 V 5,000 1975 Steel OS TK Farm Yes No Concrete Block

Silicone 1 V 4,000 1971 Steel 9 x 14 OS TK Farm Yes No Concrete Block

2 V 2,000 1971 Steel Yes Concrete Block

40 H 3,000 1968 Steel Run Room Yes Yes Concrete Block

FR Add. 28 V 5,000 1963 Steel 9 x 11 Lower TK R Yes Yes Concrete Block

29 V 5,000 1963 Steel 9 x 11 Lower TK R Yes Yes Concrete Block

30 V 5,000 1972 Steel 8.5 x 12 Lower TK R Yes Yes Concrete Block

31 V 5,000 1977 Steel 8.5 x 12 Lower TK R Yes Yes Concrete Block

Amine 32 H 1,000 ?? Steel Lower TK R Yes Yes Concrete Block

TEOA 33 V 5,000 1970 Steel 8 x 13.5 PIPA Room Yes Yes Concrete Block

DEOA 34 V 5,000 1970 Steel 8 x 13.5 PIPA Room Yes Yes Concrete Block