FORM A-1

PARENT COMPANY INFORMATION

I. Parent Company / Legal Corporate Owner Information

 1. Legal Parent Company / Legal Corporate Name Ammerock Products, LP

 2. Address 440 Jackrabbit Rd.

 3. City Nolanville

 4. State Texas

 5. Zip Code 76559

 6. County Bell

 7. Size of Company (approximate number of employees including all 

subsidiaries, branches, and related establishments owned): 33

= Confidential Business Information (CBI)
FORM A-2

FACILITY INFORMATION

II. Facility Information

 Facility Name Nolanville Plant

 Facility Address

 Street 440 Jackrabbit Rd.

 City Nolanville

 State Texas

 Zip Code 76559

 County Bell

 Facility Coordinates

 Latitude (decimal degrees, six decimal places) 31.078943

 Longitude (decimal degrees, six decimal places) -97.574136

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

centroid of property, etc.) North corner of property line

 Number of employees attached to the mineral wool production 

facility: Confidential Business Information (CBI)

 Design capacity of the plant (tons/yr) CBI

 Type(s) of process(es) (rotary spin, flame attenuation) at this plant Single wheel down spinning

 Operation schedule

 hrs/day 24

 days/yr 365

 Identify what state and local air pollution rules and regulations, 

including permit requirements, your plant is subject to. (Please 

provide copies of permit(s) and permit IDs) See attached Permit Nos. 9397 and O1134

III. Technical Contact

 Name Lee Houlditch

 Technical Contact Title General Manager

 Telephone (205) 516-9164

 Facsimile (Fax) (205) 655-0196

 Email lhoulditch@amerrock.com
IV. Other

 Is the facility a major source of HAP? Yes

 

 If "No", did the facility take a limit of its potential HAP emissions 

to avoid classification as a major source? N/A

 Does the facility manufacture other products in addition to 

mineral wool? No

 If "Yes", list the other products manufactured at the facility. N/A

 Are there any HAP emissions associated with any co-located 

facilities? List unit operations, e.g., boiler, and pollutant/emissions No
FORM B-1

PLANT OPERATIONS

I. Overview of Process Operations

Number of process lines. Include lines that are currently

operational or that are temporarily shutdown. (Do not 

include lines permanently shutdown). 2

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

Process line identification name or numbers Cupola 1 Cupola 2 N/A

Type of process line (e.g., Fiberization method) Single wheel down spinning

Single wheel down 

spinning N/A

Maximum annual production rate (tons/yr) CBI CBI N/A

Age of process line (yrs) 24 24 N/A

Remaining economic life of process line (yrs) N/A N/A N/A

List of products produced and most recent annual 

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

Please attach detailed schematics of each process line Not available Not available N/A
FORM B-2

PROCESS OPERATIONS

II. Raw Material Handling and Storage

 Cupola charge preparation

 Raw materials and proportions by wt (%) CBI

 Method(s) of conveying each raw material to cupola Conveyor belt/skip hoist

 Binder and Additives

 List each raw material, including premixed materials, in 

the binder formulation and its proportion by wt (%) N/A - No binder used

 List steps in preparing binder, including storage 

temperature (°F) and holding time (hrs) N/A

 Total yearly consumption of binder, excluding water, 

(gal/yr) N/A

 Cost of binder, excluding water, ($/gal) for most recent 

year (specify year) N/A

 Are binder storage and mixing tanks vented to 

outside/inside? N/A

 Method of treating vent air from storage and mix tanks N/A

 Emission control during liquid raw material transfer from 

vehicles to storage tanks. N/A

 Describe future source reduction plans and schedules to 

reformulate binders; List each constituent, proportions wt 

(%), cost ($/gal) for reformulation N/A
FORM B-3

PROCESS OPERATIONS

III. Cupola/furnace

 For each cupola: Cupola 1 Cupola 2 Cupola 3

 Process unit identification name/number Cupola 1 Cupola 2 N/A

 Process line(s) served (identification name/number) Cupola 1 Cupola 2 N/A

 Latitude (decimal degrees, six decimal places) 31.075285 31.075149 N/A

 Longitude (decimal degrees, six decimal places) -97.570543 -97.570482 N/A

 Stack or vent height (units)

195 ft (shared with 

Cupola 2)

195 ft (shared with 

Cupola 1) N/A

 Stack or vent diameter (units) 3.4 ft 3.4 ft N/A

 Manufacturer and model N/A N/A N/A

 Date of original installation 1986 1986 N/A

 Estimate of remaining lifetime (yrs) N/A N/A N/A

 Major rebuilds:

 What constitutes a major rebuild * * N/A

 Frequency of a major rebuild N/A N/A N/A

 Cost of typical major rebuild N/A N/A N/A

 Date of last major rebuild N/A N/A N/A

 Purpose of last major rebuild N/A N/A N/A

 Increase or decrease in emissions N/A N/A N/A

 Fuel type: coke, electric, gas, or oil Coke Coke N/A

 Fuel consumption rate (KW/ton of melt or Btu/ton of melt) CBI CBI N/A

 Design production rate (tons/day) CBI CBI N/A

 Actual glass pull rate (tons/day) N/A N/A N/A

 Exhaust air flow rate (acfm @ °F) 30,000 (at 130°F) 30,000 (at 130°F) N/A

 Temperature (°F) of melt as it exits the cupola 2500°F 2500°F N/A

 Is oxygen enrichment used to supplement combustion air Yes Yes N/A

 Quantity of oxygen supplied for enrichment (cu. Ft. O2/ton 

coke) CBI CBI N/A

 Nature and frequency of routine/preventive maintenance 

procedures

Maintenance 

performed on as 

needed basis

Maintenance 

performed on as 

needed basis N/A

 Describe process modification(s) since 1999 that reduce 

emissions None** None** N/A

 Describe future source reduction plans and schedules None** None** N/A
*The industry is not familiar with the term “major rebuild.” 

Federal and state regulators have agreed that a furnace, 

cupola, or melter refractory rebricking or lining replacement is 

properly categorized as routine maintenance, repair, or 

replacement (“RMRR”), which covers a wide variety of 

activities.

**The products manufactured at this facility are used to make 

buildings more energy efficient. A thermally-efficient building 

reduces the energy required to maintain a comfortable indoor 

environment. A decrease in energy consumption conserves 

non-renewable fuel supplies and reduces air pollution and 

greenhouse gas emissions such as carbon dioxide (CO2) and 

nitrogen oxide (NOx). According to a Harvard University

School of Public Health study, thermal insulation’s reduction 

of emissions greatly improves public health.
FORM B-4

PROCESS OPERATIONS

IV. Fiberization

 For each fiberization operation: Fiberization Operation 1 Fiberization Operation 2 Fiberization Operation 3

 Process unit identification name/number Cupola 1 Cupola 2 N/A

 Process line(s) served (identification name/number) Cupola 1 Cupola 2 N/A

 Latitude (decimal degrees, six decimal places) 31.075285 31.075149 N/A

 Longitude (decimal degrees, six decimal places) -97.570543 -97.570482 N/A

 Stack or vent height (units) None None N/A

 Stack or vent diameter (units) None None N/A

 Number of fiber forming devices (spinners) per line 1 1 N/A

 Method of attenuation fiber (air, centrifical force, or both) Both Both N/A

 Major rebuilds:

 What constitutes a major rebuild * * N/A

 Frequency of a major rebuild N/A N/A N/A

 Cost of typical major rebuild N/A N/A N/A

 Date of last major rebuild N/A N/A N/A

 Purpose of last major rebuild N/A N/A N/A

 Increase or decrease in emissions N/A N/A N/A

 If forming section is modular, i.e., more than one forming 

and collection area per line, indicate the number of modules and 

air plenums. None None N/A

 Presence of water overspray and application range (gpm) None None N/A

 Binder applied and application rate (gpm) None None N/A

 Other material applied (annealing oil or oil/water emulsion) 

and application rate (gpm) Annealing oil, 0.0625 gpm Annealing oil, 0.0625 gpm N/A

 Temperature of binder when applied to the fibers (°F) None None N/A

 Forming air flow rate (acfm @ °F) Not a bonded line Not a bonded line N/A

 Percent of forming air recirculated and percent exhausted N/A N/A N/A

 Nature and frequency of routine/preventive maintenance 

procedures

Maintenance performed on 

as needed basis

Maintenance performed on 

as needed basis N/A

 Describe process modification(s) since 1999 that reduce 

emissions None** None** N/A

 Describe future source reduction plans and schedules None** None** N/A

 Fiberization method (e.g., Downey process or Youger/Powell 

process)

Single wheel down 

spinning Single wheel down spinning N/A
 Number of rotors 1 1 N/A

 Configuration of rotor(s) Vertical Vertical N/A

 Amount of material that remains non-fiberized shot 24.30% 27.80% N/A

 Exhaust air flow rate (acfm @ °F) 180,503 @ 103°F 180,503 @ 103°F N/A

*The industry is not familiar with the term “major rebuild.” 

Federal and state regulators have agreed that a furnace, cupola, 

or melter refractory rebricking or lining replacement is properly

categorized as routine maintenance, repair, or replacement 

(“RMRR”), which covers a wide variety of activities.

**The products manufactured at this facility are used to make 

buildings more energy efficient. A thermally-efficient building 

reduces the energy required to maintain a comfortable indoor 

environment. A decrease in energy consumption conserves nonrenewable fuel supplies and reduces air pollution and 

greenhouse gas emissions such as carbon dioxide (CO2) and 

nitrogen oxide (NOx). According to a Harvard University School 

of Public Health study, thermal insulation’s reduction of 

emissions greatly improves public health.
FORM B-5

PROCESS OPERATIONS

V. Fiber Collection

 For each fiber collection operation: Fiber Collection Operation 1 Fiber Collection Operation 2 Fiber Collection Operation 3

 Process unit identification name/number N/A - Not a bonded line N/A - Not a bonded line N/A - Not a bonded line

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

 Latitude (decimal degrees, six decimal places) N/A N/A N/A

 Longitude (decimal degrees, six decimal places) N/A N/A N/A

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

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

 Method of fiber collection from fiberization N/A N/A N/A

 Manufacturer and model of collection chamber N/A N/A N/A

 Date of original installation N/A N/A N/A

 Major rebuilds:

 What constitutes a major rebuild N/A N/A N/A

 Frequency of a major rebuild N/A N/A N/A

 Cost of typical major rebuild N/A N/A N/A

 Date of last major rebuild N/A N/A N/A

 Purpose of last major rebuild N/A N/A N/A

 Increase or decrease in emissions N/A N/A N/A

 Air flow rate (acfm @ °F) in pneumatic fiber conveying N/A N/A N/A

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

 Residence time of product (mins) (time spent in 

collection device) N/A N/A N/A

 Method of evenly distributing fibers onto conveyor belt N/A N/A N/A

 Formed mat thickness (in.) N/A N/A N/A

 Nature and frequency of routine/preventive 

maintenance procedures N/A N/A N/A

 Describe process modification(s) since 1999 that 

reduce emissions N/A N/A N/A

 Describe future source reduction plans and schedules N/A N/A N/A
FORM B-6

PROCESS OPERATIONS

VI. Curing 

 For each curing oven: Curing Oven 1 Curing Oven 2 Curing Oven 3

 Process unit identification name/number N/A - No Curing Oven N/A - No Curing Oven N/A - No Curing Oven

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

 Latitude (decimal degrees, six decimal places) N/A N/A N/A

 Longitude (decimal degrees, six decimal places) N/A N/A N/A

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

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

 Method of curing N/A N/A N/A

 Manufacturer and model N/A N/A N/A

 Date of original installation N/A N/A N/A

 Major rebuilds:

 What constitutes a major rebuild N/A N/A N/A

 Frequency of a major rebuild N/A N/A N/A

 Cost of typical major rebuild N/A N/A N/A

 Date of last major rebuild N/A N/A N/A

 Purpose of last major rebuild N/A N/A N/A

 Increase or decrease in emissions N/A N/A N/A

 Fuel type: electric, gas, or oil N/A N/A N/A

 Fuel consumption rate (KW/hr or BTU/hr) N/A N/A N/A

 Curing temperature (°F) N/A N/A N/A

 Moisture content wt (%) of formed mat: 

 inlet N/A N/A N/A

 outlet N/A N/A N/A

 Exhaust air flow rate (acfm @ °F) from curing N/A N/A N/A

 Residence time of product (mins) N/A N/A N/A

 Binder content of cured product (LOI) N/A N/A N/A

 Nature and frequency of routine/preventive maintenance 

procedures N/A N/A N/A

 Describe process modification(s) since 1999 that reduce 

emissions N/A N/A N/A

 Describe future source reduction plans and schedules N/A N/A N/A
FORM B-7

PROCESS OPERATIONS

VII. Cooling

 For each cooling operation: Cooling Operation 1 Cooling Operation 2 Cooling Operation 3

 Process unit identification name/number N/A - No Cooling Operation N/A - No Cooling Operation N/A - No Cooling Operation

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

 Latitude (decimal degrees, six decimal places) N/A N/A N/A

 Longitude (decimal degrees, six decimal places) N/A N/A N/A

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

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

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

 Percentage of cooling air recirculated (if any) N/A N/A N/A

 Cooling air temperature (°F) N/A N/A N/A

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

 Nature and frequency of routine/preventive maintenance 

procedures N/A N/A N/A

 Describe process modification(s) since 1999 that reduce 

emissions N/A N/A N/A

 Describe future source reduction plans and schedules N/A N/A N/A
FORM B-8

PROCESS OPERATIONS

VIII. Pollution Prevention

Please describe any work practices, pollution prevention techniques, 

and control strategies evaluated and/or implemented at each process 

unit at your facility (e.g., binder reformulation, alternative fuels usage, 

etc.) to reduce emissions of PM, CO, and HAPs you identified in Form 

E. You must specify the year in which the facility implemented the 

practice/technique and identify the emission reductions (if measured) 

from these practices/techniques.

O2 injection system implemented 1996; reduced CO emissions 

by approximately 34%.

Evaluated addition of lime to melt in 1995; was tested but not 

implemented permanently.
FORM C-1

AIR POLLUTION CONTROL

I. Electrostatic Precipitator (ESP)

 For each ESP: ESP 1 ESP 2 ESP 3

 Process line(s) (identification name/number) N/A - No ESP N/A - No ESP N/A - No ESP

 Equipment/process(es) controlled. Include emission point 

designations (e.g., E3, E4 from plot plan) N/A N/A N/A

 Latitude (decimal degrees, six decimal places) N/A N/A N/A

 Longitude (decimal degrees, six decimal places) N/A N/A N/A

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

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

 Manufacturer and model N/A N/A N/A

 Date of original installation N/A N/A N/A

 Number of collection plates and configuration N/A N/A N/A

 Gas flow rate to ESP (acfm @ °F) N/A N/A N/A

 Inlet gas temperature (°F) N/A N/A N/A

 Outlet gas temperature (°F) N/A N/A N/A

 Inlet grain loading (gr/dscf) N/A N/A N/A

 Outlet grain loading (gr/dscf) N/A N/A N/A

 Average stack opacity (%) N/A N/A N/A

 Pressure drop across ESP (in. H2O gauge) N/A N/A N/A

 Plate area (ft2) N/A N/A N/A

 Vendor guarantee on ESP efficiency (attach copy) N/A N/A N/A

 Method of plate cleaning and frequency N/A N/A N/A

 Flow rate of plate wash water to ESP (gpm), if applicable N/A N/A N/A

 Temperature of plate wash water to ESP (°F), if applicable N/A N/A N/A

 Source of plate wash water used for cleaning, if applicable N/A N/A N/A

 Concentration (mg/l) of dissolved and suspended solids in plate 

wash water, if applicable N/A N/A N/A

 Conditioning agents used and amounts (in gpm or lbs/hr), if 

applicable N/A N/A N/A

 Amount of wastewater generated (gpd), if applicable N/A N/A N/A

 Amount of wastewater recycled (gpd), if applicable N/A N/A N/A

 Amount of wastewater disposed of (gpd), if applicable N/A N/A N/A

 Method of wastewater disposal, if applicable N/A N/A N/A

 Quantity of solid waste collected (lbs/yr) N/A N/A N/A

 Quantity of solid waste recycled (lbs/yr) N/A N/A N/A

 Quantity of solid waste disposed of (lbs/yr) N/A N/A N/A
 Method of solid waste disposal N/A N/A N/A

 Nature and frequency of routine/preventive maintenance 

procedures N/A N/A N/A

 Problems experienced with control device within the last five 

years; how were problems solved? N/A N/A N/A

 Continuous monitoring method(s) used to monitor ESP 

performance, including parameters monitored N/A N/A N/A

 Describe any plans to replace or upgrade ESP N/A N/A N/A
FORM C-2

AIR POLLUTION CONTROL

II. Scrubber

 For each scrubber: Scrubber 1 Scrubber 2 Scrubber 3

 Process line(s) (identification name/number) Cupola 1 and Cupola 2 N/A N/A

 Equipment/process(es) controlled. Include emission point 

designations (e.g., E3, E4 from plot plan) Cupola 1 and Cupola 2 N/A N/A

 Latitude (decimal degrees, six decimal places) 31.075306 N/A N/A

 Longitude (decimal degrees, six decimal places) -97.570836 N/A N/A

 Stack or vent height (units) 75 ft N/A N/A

 Stack or vent diameter (units) 12 ft N/A N/A

 Manufacturer and model N/A N/A N/A

 Date of original installation N/A N/A N/A

 Type (e.g., venturi, orifice) Spray column N/A N/A

 Gas flow rate to scrubber (acfm @ °F) 180,503 @ 103°F N/A N/A

 Inlet gas temperature (°F) Unknown N/A N/A

 Outlet gas temperature (°F) 103°F N/A N/A

 Inlet grain loading (gr/dscf) Unknown N/A N/A

 Outlet grain loading (gr/dscf) 0.015 N/A N/A

 Average stack opacity (%)

<10% per permit; typical 

opacity 0% N/A N/A

 Water flow rate to scrubber (gpm) > 245 gpm per permit N/A N/A

 Percent of scrubber water from recycled wastewater Closed loop system N/A N/A

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

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

Recycle with fresh water 

addition from well; no 

pretreatment N/A N/A

 HAP composition of wastewater (mg/L) Unknown N/A N/A

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

scrubbing water Unknown N/A N/A

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

 Liquid/gas ratio (gal/103 acfm) >1.35 N/A N/A

 Pressure drop across scrubber (in. H2O gauge) N/A - spray column N/A N/A

 Amount of wastewater generated (gpd) 352,800 gpd N/A N/A
 Amount of wastewater recycled (gpd) 352,800 gpd N/A N/A

 Amount of wastewater disposed of (gpd) None N/A N/A

 Method of wastewater disposal N/A N/A N/A

 Quantity of solid waste collected (lbs/yr) 40,000 N/A N/A

 Quantity of solid waste recycled (lbs/yr) 0 N/A N/A

 Quantity of solid waste disposed of (lbs/yr) 40,000 N/A N/A

 Method of solid waste disposal Land spreading N/A N/A

 Vendor guarantee on scrubber efficiency (attach copy) N/A N/A N/A

 Nature and frequency of preventive maintenance procedures

Daily visual inspection of 

spray nozzles N/A N/A

 Problems experienced with control device within the last five years; 

how were problems solved?

Clogged nozzles were 

cleaned N/A N/A

 Continuous monitoring method(s) used to monitor scrubber 

performance, including parameters monitored

Daily record of water flow 

rate to scrubber N/A N/A

 Plans to replace or upgrade scrubber None N/A N/A
FORM C-3

AIR POLLUTION CONTROL

III. Mechanical Collector

 For each mechanical collector: Mechanical Collector 1 Mechanical Collector 2 Mechanical Collector 3

 Process line(s) (identification name/number)

N/A - No mechanical 

collector

N/A - No mechanical 

collector

N/A - No mechanical 

collector

 Equipment/process(es) controlled. Include emission point 

designations (e.g., E3, E4 from plot plan) N/A N/A N/A

 Latitude (decimal degrees, six decimal places) N/A N/A N/A

 Longitude (decimal degrees, six decimal places) N/A N/A N/A

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

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

 Manufacturer and model N/A N/A N/A

 Date of original installation N/A N/A N/A

 Type of mechanical collector N/A N/A N/A

 Gas flow rate to collector (acfm @ °F) N/A N/A N/A

 Inlet gas temperature (°F) N/A N/A N/A

 Outlet gas temperature (°F) N/A N/A N/A

 Inlet grain loading (gr/dscf) N/A N/A N/A

 Outlet grain loading (gr/dscf) N/A N/A N/A

 Average stack opacity (%) N/A N/A N/A

 Overall pressure drop (in. H2O gauge) N/A N/A N/A

 Vendor guarantee on mechanical collector efficiency (attach 

copy) N/A N/A N/A

 Quantity of solid waste collected (lbs/yr) N/A N/A N/A

 Quantity of solid waste recycled (lbs/yr) N/A N/A N/A

 Quantity of solid waste disposed of (lbs/yr) N/A N/A N/A

 Method of solid waste disposal N/A N/A N/A

 Nature and frequency of preventive maintenance procedures N/A N/A N/A

 Problems experienced with control device within the last five 

years; how were problems solved? N/A N/A N/A
 Continuous monitoring method(s) used to monitor performance, 

including parameters monitored N/A N/A N/A

 Plans to replace or upgrade mechanical collector N/A N/A N/A
FORM C-4

AIR POLLUTION CONTROL

IV. Fabric Filter 

 For each fabric filter: Fabric Filter 1 Fabric Filter 2 Fabric Filter 3

 Process line(s) (identification name/number) Cupola 1 Cupola 2 N/A

 Equipment/process(es) controlled. Include emission point 

designations (e.g., E3, E4 from plot plan) Cupola 1 Cupola 2 N/A

 Latitude (decimal degrees, six decimal places) 31.075474 31.075491 N/A

 Longitude (decimal degrees, six decimal places) -97.570498 -97.570445 N/A

 Stack or vent height (units)

195 ft (shared with Cupola 

2)

195 ft (shared with Cupola 

1) N/A

 Stack or vent diameter (units) 3.4 ft 3.4 ft N/A

 Manufacturer and model N/A N/A N/A

 Date of original installation 1986 1986 N/A

 Number of compartments 4 4 N/A

 Number of bags per compartment 140 140 N/A

 Filter material and coatings applied Polyester felt Polyester felt N/A

 Fabric weight (oz/yd

2

) 16 oz/sqyd 16 oz/sqyd N/A

 Filter surface area (ft2) 13,120 13,120 N/A

 Gas flow rate to filter (acfm @ °F) 30,000 (at 130°F) 30,000 (at 130°F) N/A

 Inlet gas temperature (°F) 130°F 130°F N/A

 Outlet gas temperature (°F) 130°F 130°F N/A

 Inlet grain loading (gr/dscf) Unknown Unknown N/A

 Outlet grain loading (gr/dscf) 0.015 0.015 N/A

 Average stack opacity (%)

<10% per permit; typical 

opacity 0%

<10% per permit; typical 

opacity 0% N/A

 Overall pressure drop (in. H2O gauge) N/A N/A N/A

 Method and frequency of bag cleaning

Mechanical shaking once 

per hour for 2 minutes

Mechanical shaking once 

per hour for 2 minutes N/A

 Vendor guarantee on fabric filter efficiency (attach copy) N/A N/A N/A

 Quantity of solid waste collected (lbs/yr) 20,000 20,000 N/A

 Quantity of solid waste recycled (lbs/yr) 0 0 N/A
 Quantity of solid waste disposed of (lbs/yr) 20,000 20,000 N/A

 Method of solid waste disposal On-site landfill On-site landfill N/A

 Nature and frequency of preventive maintenance 

procedures

Maintenance performed on 

as needed basis

Maintenance performed on 

as needed basis N/A

 Problems experienced with control device within the last five 

years; how were problems solved? PLC Rack replaced PLC Rack replaced N/A

 Continuous monitoring method(s) used to monitor 

performance, including parameters monitored

Bag leak detection system, 

per MACT DDD

Bag leak detection system, 

per MACT DDD N/A

 Plans to replace or upgrade fabric filter None None N/A
FORM C-4

AIR POLLUTION CONTROL

IV. Fabric Filter 

 For each fabric filter:

 Process line(s) (identification name/number)

 Equipment/process(es) controlled. Include emission point 

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

 Latitude (decimal degrees, six decimal places)

 Longitude (decimal degrees, six decimal places)

 Stack or vent height (units)

 Stack or vent diameter (units)

 Manufacturer and model

 Date of original installation

 Number of compartments

 Number of bags per compartment

 Filter material and coatings applied

 Fabric weight (oz/yd

2

)

 Filter surface area (ft2)

 Gas flow rate to filter (acfm @ °F)

 Inlet gas temperature (°F)

 Outlet gas temperature (°F)

 Inlet grain loading (gr/dscf)

 Outlet grain loading (gr/dscf)

 Average stack opacity (%)

 Overall pressure drop (in. H2O gauge)

 Method and frequency of bag cleaning

 Vendor guarantee on fabric filter efficiency (attach copy)

 Quantity of solid waste collected (lbs/yr)

 Quantity of solid waste recycled (lbs/yr)
 Quantity of solid waste disposed of (lbs/yr)

 Method of solid waste disposal

 Nature and frequency of preventive maintenance 

procedures

 Problems experienced with control device within the last five 

years; how were problems solved?

 Continuous monitoring method(s) used to monitor 

performance, including parameters monitored

 Plans to replace or upgrade fabric filter

 
FORM C-5

AIR POLLUTION CONTROL

V. Thermal Incinerator

 For each thermal incinerator Thermal Incinerator 1 Thermal Incinerator 2 Thermal Incinerator 3

 Process line(s) (identification name/number)

N/A - No Thermal 

Incinerator

N/A - No Thermal 

Incinerator

N/A - No Thermal 

Incinerator

 Equipment/process(es) controlled. Include emission point 

designations (e.g., E3, E4 from plot plan) N/A N/A N/A

 Latitude (decimal degrees, six decimal places) N/A N/A N/A

 Longitude (decimal degrees, six decimal places) N/A N/A N/A

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

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

 Manufacturer and model N/A N/A N/A

 Date of original installation N/A N/A N/A

 Fuel type: gas or oil N/A N/A N/A

 Fuel consumption rate (BTU/hr) N/A N/A N/A

 Inlet gas flow rate (acfm @ °F) N/A N/A N/A

 Inlet gas temperature (°F) N/A N/A N/A

 Combustion chamber gas temperature (°F) N/A N/A N/A

 Outlet gas temperature (°F) N/A N/A N/A

 Inlet grain loading (gr/dscf) N/A N/A N/A

 Outlet grain loading (gr/dscf) N/A N/A N/A

 Average stack opacity (%) N/A N/A N/A

 Excess air (%) N/A N/A N/A

 Residence time (sec) at temperature (°F) N/A N/A N/A

 Percent heat recovery N/A N/A N/A

 Vendor guarantee on incinerator efficiency (attach copy) N/A N/A N/A

 Nature and frequency of preventive maintenance procedures N/A N/A N/A

 Problems experienced with control device within the last five 

years; how were problems solved? N/A N/A N/A

 Continuous monitoring method(s) used to monitor incinerator 

performance, including parameters monitored N/A N/A N/A
 Plans to replace or upgrade thermal incinerator N/A N/A N/A
FORM C-6

AIR POLLUTION CONTROL

VI. High Velocity Air Filter (HVAF)

 For each HVAF: HVAF 1 HVAF 2 HVAF 3

 Process line(s) (identification name/number) N/A - No HVAF N/A - No HVAF N/A - No HVAF

 Equipment/process(es) controlled. Include emission 

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

 Latitude (decimal degrees, six decimal places) N/A N/A N/A

 Longitude (decimal degrees, six decimal places) N/A N/A N/A

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

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

 Manufacturer and model N/A N/A N/A

 Date of original installation N/A N/A N/A

 Inlet gas flow rate (acfm @ °F) N/A N/A N/A

 Inlet gas temperature (°F) N/A N/A N/A

 Outlet gas temperature (°F) N/A N/A N/A

 Inlet grain loading (gr/dscf) N/A N/A N/A

 Outlet grain loading (gr/dscf) N/A N/A N/A

 Average stack opacity (%) N/A N/A N/A

 Water spray pressure (psig), if applicable N/A N/A N/A

 Water spray rate (gpm), if applicable N/A N/A N/A

 Filter face velocity (acfm/ft2) N/A N/A N/A

 Maximum pressure drop across mat (in. H2O gauge) N/A N/A N/A

 Vendor guarantee on HVAF efficiency (attach copy) N/A N/A N/A

 Method and frequency of filter mad advancement N/A N/A N/A

 Amount of wastewater generated (gpd) N/A N/A N/A

 Amount of wastewater recycled (gpd) N/A N/A N/A

 Amount of wastewater disposed of (gpd) N/A N/A N/A

 Method of wastewater disposal N/A N/A N/A

 Quantity of solid waste collected (lbs/yr) N/A N/A N/A

 Quantity of solid waste recycled (lbs/yr) N/A N/A N/A

 Quantity of solid waste disposed of (lbs/yr) N/A N/A N/A
 Method of solid waste disposal N/A N/A N/A

 Nature and frequency of preventive maintenance 

procedures N/A N/A N/A

 Problems experienced with control device within the last 

five years; how were problems solved? N/A N/A N/A

 Continuous monitoring method(s) used to monitor 

HVAF performance, including parameters monitored N/A N/A N/A

 Plans to replace or upgrade HVAF N/A N/A N/A
FORM C-7

AIR POLLUTION CONTROL

VII. Mist Eliminator

 For each mist eliminator: Mist Eliminator 1 Mist Eliminator 2 Mist Eliminator 3

 Process line(s) (identification name/number) N/A - No Mist Eliminator N/A - No Mist Eliminator N/A - No Mist Eliminator

 Equipment/process(es) controlled. Include emission point 

designations (e.g., E3, E4 from plot plan) N/A N/A N/A

 Latitude (decimal degrees, six decimal places) N/A N/A N/A

 Longitude (decimal degrees, six decimal places) N/A N/A N/A

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

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

 Manufacturer and model N/A N/A N/A

 Date of original installation N/A N/A N/A

 Type of mist eliminator N/A N/A N/A

 Gas flow rate to mist eliminator (acfm @ °F) N/A N/A N/A

 Inlet gas temperature (°F) N/A N/A N/A

 Outlet gas temperature (°F) N/A N/A N/A

 Inlet grain loading (gr/dscf) N/A N/A N/A

 Outlet grain loading (gr/dscf) N/A N/A N/A

 Average stack opacity (%) N/A N/A N/A

 Velocity in mist eliminator (ft/sec) N/A N/A N/A

 Pressure drop (in. H2O gauge) N/A N/A N/A

 For chevron blade mist eliminators: N/A N/A N/A

 Spacing between blades (in.) N/A N/A N/A

 Washing frequency of blades N/A N/A N/A

 For mesh pad mist eliminators: N/A N/A N/A

 Number of pads or elements N/A N/A N/A

 Thickness of pad (in.) or element dimensions N/A N/A N/A

 Density of pad, (lb/ft3) N/A N/A N/A

 Washing frequency of pad N/A N/A N/A

 Vendor guarantee on mist eliminator efficiency (attach copy) N/A N/A N/A
 Amount of wastewater generated (gpd) N/A N/A N/A

 Amount of wastewater recycled (gpd) N/A N/A N/A

 Amount of wastewater disposed of (gpd) N/A N/A N/A

 Method of wastewater disposal N/A N/A N/A

 Quantity of solid waste collected (lbs/yr) N/A N/A N/A

 Quantity of solid waste recycled (lbs/yr) N/A N/A N/A

 Quantity of solid waste disposed of (lbs/yr) N/A N/A N/A

 Method of solid waste disposal N/A N/A N/A

 Nature and frequency of preventive maintenance procedures N/A N/A N/A

 Problems experienced with control device within the last five 

years; how were problems solved? N/A N/A N/A

 Continuous monitoring method(s) used to monitor mist eliminator 

performance, including parameters monitored N/A N/A N/A

 Plans to replace or upgrade mist eliminator N/A N/A N/A
FORM C-8

AIR POLLUTION CONTROL

VIII. Ventilation System 

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

 Process line(s) (identification name/number)

N/A - No Applicable 

Ventilation System

N/A - No Applicable 

Ventilation System

N/A - No Applicable 

Ventilation System

 Equipment/process(es) controlled. Include emission point 

designations (e.g., E3, E4 from plot plan) N/A N/A N/A

 Latitude (decimal degrees, six decimal places) N/A N/A N/A

 Longitude (decimal degrees, six decimal places) N/A N/A N/A

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

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

 For general or building ventilation:

 Ventilation system used N/A N/A N/A

 Airflow control system used N/A N/A N/A

 Number of air changes per hour N/A N/A N/A

 For unit or local ventilation:

 Enclosure or hood design used N/A N/A N/A

 Volume of enclosure or hood N/A N/A N/A

 Capture velocity (ft/sec) N/A N/A N/A

 Distance between hood and emission source (ft) N/A N/A N/A
FORM C-9

AIR POLLUTION CONTROL

IX. Other 

 For each other air pollution control devide (APCD): Other APCD 1 Other APCD 2 Other APCD 3

 Process line(s) (identification name/number) N/A - No Other APCD N/A - No Other APCD N/A - No Other APCD

 Equipment/process(es) controlled. Include emission point 

designations (e.g., E3, E4 from plot plan) N/A N/A N/A

 Latitude (decimal degrees, six decimal places) N/A N/A N/A

 Longitude (decimal degrees, six decimal places) N/A N/A N/A

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

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

 Description N/A N/A N/A
FORM D

PROCESS LINE STARTUP AND SHUTDOWN

1. For each startup and shutdown (SS) that occurred during the past 

five years, please provide the following information requested in A. 

through J. 

 A. Using the definitions provided above, indicate whether the 

event was a startup or shutdown; N/A - Not relevant for mineral wool cupolas

 B. A description of the event, including identification of the 

emissions source or sources associated with the startup or 

shutdown; N/A

 C. Whether any permit condition was exceeded and, if so, what 

permit condition was exceeded; N/A

 D. Whether the event was covered by any contingency plan for 

controlling emissions during startup and shutdown events and, if so, 

whether the plan was followed; if the plan was not followed, why not; N/A

 E. The duration of the event; N/A

 F. The actions taken to minimize emissions during the event, 

including the use of any backup control systems; N/A

 G. Estimates or measurements, if any, of emissions during the 

event; if you did not have the ability to quantify emissions during the 

event, please explain why; N/A

 H. Whether the emission profile of each unit was different during 

startup and shutdown than during normal operating conditions and, if 

so, how emissions were different and why; please provide any

supporting information; N/A

 I. All performance test data collected during each period of SS; 

the test method used for each event; when the testing was 

conducted and why; the test conditions at the time of testing; and 

whether the tests were associated with a routine startup or shutdown; 

and N/A

 J. All monitoring data, including control system parameter 

monitoring, collected during each period of SS. N/A

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

Shutdown: the cessation of operation of an affected source or portion of an affected source for any purpose.
If this information is contained in periodic and immediate SS reports 

(either stand-alone or contained within the periodic excess emissions 

report) submitted to your permitting authority, you may submit copies 

of those reports instead.

2. Are there any types of startup or shutdown events that you have 

been able to eliminate? If so, please describe the type of event and 

explain how these events were eliminated. N/A

3. Please submit a copy of your SS plan if you are required to 

develop one. N/A

4. Please provide all performance test data collected during periods 

of SS over the last 5 years. Indicate the test method used for each 

event. N/A

5. Please provide all monitoring data, including control system 

parameter monitoring, collected during periods of SS over the last 5 

years. N/A

6. Optional: Do you wish to recommend a standard that would apply

during startup or shutdown? If so, please describe the event to 

which the standard would apply; the recommended standard (this 

could be an emission limitation, work practice, or operational 

standard) that would apply during the period; the basis for the 

recommended standard; why and how the standard would minimize 

emissions during the event; and how would compliance be 

determined and/or monitored. N/A
FORM E

PRESENCE OF AIR POLLUTANTS IN EMISSION POINTS

Please provide any existing emissions information and data covering 

hazardous air pollutants (HAP), particulate matter (PM), and carbon 

monoxide (CO) for each listed process. Identify the appropriote box for 

which you are providing specific process inofrmation and/or pollutant 

emissions data.

Cupola Fiberization Fiber Collection Curing Cooling

Carbon monoxide (CO) * * N/A N/A N/A

Carbonyl sulfide (COS) * * N/A N/A N/A

Particulate Matter (PM, PM2.5, PM10, PM condensable) * * N/A N/A N/A

Chromium compounds and Hexavalent Chromium (including any Cr 

speciation data) * * N/A N/A N/A

Other metal HAP (As, Be, Cd, Co, Hg, Pb, Mn, Sb, Se) * * N/A N/A N/A

Hydrogen Fluoride (HF) * * N/A N/A N/A

Hydrogen Chloride (HCl) N/A N/A N/A N/A N/A

Formaldehyde N/A N/A N/A N/A N/A

Phenol N/A N/A N/A N/A N/A

Methanol N/A N/A N/A N/A N/A

Other organic HAP N/A N/A N/A N/A N/A

* Already provided by NAIMA and/or to be provided through the “BTEC, 

Inc. Quality Assurance Project Plan for the Mineral Wool and Wool 

Fiberglass Emissions Test Program.”
FORM F-1 

COST

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

The Company does not 

capture cost by individual 

line

The company does not 

capture cost by

individual line

Line one and line two 

combined

 For each process unit: Process Unit 1 Process Unit 2 Line 1 + Line 2

 Process Unit ID Cupola 1 Cupola 2 combined

 Process Line ID Cupola 1 Cupola 2 combined

II. Capital Costs

 Base year N/A

 Total capital cost, including costs for individual pieces, if available. N/A

III. Annual Operating Costs

 Base year (most recent fiscal year) 2009

 Total annual operating costs CBI

 Maintenance materials and replacement parts (specify costs by

item) CBI

 Raw materials costs CBI

 Labor

 ($/yr) for each labor class CBI

 (hr/hr) for each labor class N/A

 Utilities (breakdown for each utility) CBI

 Waste treatment and/or disposal N/A

 Costs associated with any work practices and pollution prevention 

techniques that are employed at your facility N/A

 Savings associated with heat recovery and wastewater and/or solid 

waste returned to process from APCD (or sold to another user) N/A

 Indirect costs CBI

 Other (specify) CBI

Please provide the annual report to shareholders or equivalent for 

the most recent fiscal year. If reports are not available, provide 

annual sales and profits (or profit margin) for the most recent fiscal 

year. If company is publicly owned, please provide a web link to this 

information. CBI
Identify the market range (regional, national, international) of your 

products. National

Can your product(s) be substituted by another product(s)? If so, 

please list your product(s) and substituted product(s).

There are alternatives to 

mineral wool insulation, 

but these substitutes are 

not likely to possess the 

same fire performance 

capabilities (mineral wool 

is non-flammable or noncombustible) as mineral 

wool, nor have the same 

versatility to be installed 

in various applications as 

mineral wool, nor have 

recycled content (mineral 

wool can have up to 90% 

recycled content), nor 

possess many other 

attributes of mineral wool 

insulation products. 

Therefore, while 

substitutes exist, they

lack the same 

performance 

characteristics that make 

mineral wool a unique 

insulation choice. 

Moreover, substitutes 

cannot be universally

installed or applied in the 

traditional mineral wool 

applications.

*The company objects to this request because it seeks information 

that is not relevant to the EPA Administrator’s review obligations 

pursuant to Clean Air Act Section 112(d)(6) and 112(f)(2).
FORM F-2 

COST

I. Air Pollution Control Device (APCD)

 For each APCD: APCD 1 APCD 2 APCD 3

 APCD ID N/A N/A N/A

 Process Unit ID N/A N/A N/A

II. Capital Costs

 Base year N/A N/A N/A

 APCD equipment purchase cost and what was included N/A N/A N/A

 List the cost for each piece of auxiliary equipment for each APCD not 

included above N/A N/A N/A

 Installation cost N/A N/A N/A

 Land purchase cost N/A N/A N/A

 Total capital cost N/A N/A N/A

 Method of financing APCD N/A N/A N/A

 Retrofit installation N/A N/A N/A

 Field erected or modular N/A N/A N/A

III. Annual Operating Costs

 Base year (most recent fiscal year) N/A N/A N/A

 Maintenance materials and replacement parts (specify costs by item) N/A N/A N/A

 Raw materials costs N/A N/A N/A

 Labor

 ($/yr) for each labor class N/A N/A N/A

 (hr/hr) for each labor class N/A N/A N/A

 Utilities (breakdown for each utility) N/A N/A N/A

 Waste treatment and/or disposal N/A N/A N/A

 Indirect costs N/A N/A N/A

 Other (specify) N/A N/A N/A

 Total annual operating cost (most recent fiscal year) N/A N/A N/A

Attach annual report to shareholders or equivalent for the most recent 

fiscal year CBI

The information requested above either does not exist and/or is not 

captured by the company cost system