2009 PARTICULATE MATTER EMISSION 

SOURCE TEST REPORT 

KNAUF INSULATION, GMBH 

SHASTA LAKE, CALIFORNIA 

Prepared For: 

Knauf Insulation, GmbH 

3100 Ashby Road 

Shasta Lake, California 96019 

For Submittal To: 

Shasta County Air Quality Management District 

1855 Placer Street, Suite 101 

Redding, California 96001 

Prepared By: 

Mark Stanfield 

The Avogadro Group, LLC

2825 Verne Roberts Circle 401 Pech Road 

Antioch, California 94509 Medford, Oregon 97502 

(925) 680-4300 (541) 665-0170

September 4, 2009

Knauf Insulation, GmbH September 4, 2009 

2009 PM Emission Test 

09090.6m, SCAQMD iii 

SUMMARY INFORMATION 

Source Information

Source Location: Knauf Insulation GmbH 

Shasta Lake, California Facility 

 3100 Ashby Road 

 Shasta Lake, CA 96019 

Contact: Mr. Chris Mahin 

Telephone: (317) 398-4434 

Facsimile: (317) 398-5501 

Units: Glass Melting Furnace 

Process: Fiberglass manufacturing 

Purpose: Determination of particulate matter emissions compliance 

Procedures: EPA Methods 1, 2, 3A (modified), 4, 5 and 202; Other Test 

Method (OTM) 028 

Permits to Operate: Nos. 97-PO-27a and 97-PO-28a 

 PSD Permit No. NSR-4-4-4, SAC 03-01 

Testing Company Information

Testing Firm: The Avogadro Group, LLC 

 401 Pech Road 2825 Verne Roberts Circle 

 Medford, OR 97502 Antioch, CA 94509 

Contacts: Mr. Mark Stanfield Mr. Erick Mirabella 

 Project Manager General Manager 

Telephone: (541) 665-0802 (925) 680-0935 

Facsimile: (541) 665-0179 (925) 680-4416 

Certifications: ARB Independent Tester 

Test Date: August 5, 2009 
Knauf Insulation, GmbH September 4, 2009 

2009 PM Emission Test 

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TABLE OF CONTENTS 

SECTION PAGE

1.0 INTRODUCTION ................................................................................................. 1 

2.0 SOURCE LOCATION INFORMATION ........................................................... 3 

2.1 FACILITY DESCRIPTION ........................................................................ 3 

 2.2 SAMPLING LOCATION ........................................................................... 3 

3.0 TEST DESCRIPTION .......................................................................................... 4 

3.1 PROGRAM OBJECTIVES ......................................................................... 4 

3.2 TEST CONDITIONS AND TEST PROGRAM SCHEDULE ................... 4 

 3.3 TEST PROCEDURES................................................................................. 5 

 3.3.1 Diluent Gases................................................................................... 6 

 3.3.2 Particulate Matter (5/202) ................................................................ 7 

 3.3.3 Particulate Matter (5/028) ................................................................ 7 

 3.3.4 Volumetric Flow Rate and Moisture Data ....................................... 8 

 

4.0 DISCUSSION OF RESULTS ............................................................................... 9 

APPENDICES 

A MEASUREMENT PROCEDURES.................................................................... A

B QUALITY ASSURANCE .................................................................................... B

B.1 Quality Assurance Program Summary and ARB Certification 

B.2 CEMS Performance and Equipment Calibration Data 

B.3 Calibration Gas Certificates 

C FIELD DATA SHEETS ....................................................................................... C

C.1 Sampling Location 

C.2 CEMS Test Data 

C.3 Particulate Matter Diluent Gases 

D EMISSION CALCULATIONS ........................................................................... D

D.1 General Emission Calculations 

D.2 Emission Calculation Spreadsheets 

D.3 Example Calculations 

E LABORATORY REPORTS.................................................................................E 

F PERMITS TO OPERATE .................................................................................... F 
Knauf Insulation, GmbH September 4, 2009 

2009 PM Emission Test 

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SECTION 1.0 

INTRODUCTION

The Avogadro Group, LLC (Avogadro) was contracted by Knauf GmbH (Knauf) to 

perform a series of air emission compliance tests on the glass melting furnace at their 

Shasta Lake, California facility. The testing was conducted to determine compliance 

with the particulate matter emission limitations of Permits to Operate #97-PO-27a and 

#97-PO-28a issued by the Shasta County Air Quality Management District (SCAQMD) 

and the Prevention of Significant Deterioration (PSD) Permit to Operate No. NSR 4-4-4, 

SAC 03-01 issued by the United States Environmental Protection Agency, Region IX 

(EPA). 

The test program was conducted on August 5, 2009 by Mark Stanfield, Doug Morical and 

Nishad Patel of Avogadro. Unit operations were coordinated by Randall Peterson of 

Knauf. Rob Stahl of SCAQMD was present to observe portions of the testing. The tests 

were conducted according to the July 7, 2009 source test protocol that was submitted to 

SCAQMD and EPA. 

Testing was performed to determine emissions of the following parameters: 

 Emission parameters:

 Total Particulate Matter (PM) – lb/hr, tons/yr, lb/ton of glass 

 Supporting data:

 O2 and CO2 - % volume dry 

 Stack gas volumetric flow rate (dscfm) and moisture content (%) 

This report provides descriptions of the facility and test location, descriptions of the 

testing program, test methods and procedures, test results, and a summary of our quality 

assurance program. The tests results are summarized in Table 1-1. Detailed results of 

individual test runs are presented in Section 4.0. All supporting data including process 

data, field data sheets, laboratory reports, calculations and spreadsheets are located in the 

appendices. 
Knauf Insulation, GmbH September 4, 2009 

2009 PM Emission Test 

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TABLE 1-1 

SUMMARY OF PARTICULATE MATTER TEST RESULTS 

KNAUF GMBH – GLASS MELTING FURNACE 

AUGUST 5, 2009 

Method 5/202 

Test Results 

Method 5/028 

Test Results 

Applicable 

Standards 

Stack Gas Parameters 

O2, % volume dry 20.71 20.71 -- 

CO2, % volume dry 0.454 0.454 -- 

Stack temperature, oF 142.7 142.5 -- 

Moisture content, % 2.14 2.08 -- 

Volumetric flow rate, acfm 25,109 25,896 -- 

Volumetric flow rate, dscfm 20,334 20,994 -- 

Particulate Matter (PM) -- 

F1⁄2 (filter), gr/dscf 0.0000 0.0000 --

F1⁄2 (acetone), gr/dscf 0.0002 0.0001 --

Total F1⁄2 grain loading, gr/dscf 0.0002 0.0001 --

F1⁄2 (filter), lb/hr 0.000 0.000 --

F1⁄2 (acetone), lb/hr 0.027 0.022 --

Total F1⁄2 mass emissions, lb/hr 0.027 0.022 --

B1⁄2 (aqueous), gr/dscf 0.0003 0.0003 -- 

B1⁄2 (organic), gr/dscf 0.0003 0.0003 -- 

Total B1⁄2 grain loading, gr/dscf 0.0006 0.0006 -- 

B1⁄2 (aqueous), lb/hr 0.054 0.059 -- 

B1⁄2 (organic), lb/hr 0.055 0.057 -- 

Total B1⁄2 mass emissions, lb/hr 0.109 0.116 -- 

Total grain loading, gr/dscf 0.0008 0.0008 -- 

Total mass emissions, lb/hr 0.137 0.138 1.0 

Total mass emissions, tons/yr 0.599 0.605 4.4 

Note: Tons/yr mass emissions are calculated based on 8,760 hours/yr of production. Emission data, 

expressed in lb/ton of glass units, are reported separately by Knauf. 
Knauf Insulation, GmbH September 4, 2009 

2009 PM Emission Test 

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SECTION 2.0 

SOURCE LOCATION INFORMATION

2.1 FACILITY DESCRIPTION 

Knauf Insulation GmbH operates a fiberglass manufacturing facility located in Shasta 

Lake, California. In operation since 2002, this plant produces light density glass 

insulation for use in a wide variety of residential, commercial and industrial applications. 

During this test program, emission testing was performed on the facility’s glass melting 

furnace exhaust stack. 

2.2 SAMPLING LOCATION 

The glass melting furnace exhaust stack is a vertical, cylindrical stack with a 37 inch 

diameter. The duct is equipped with two sampling ports oriented 90 degrees from each 

other on the same horizontal plane. The ports are located greater than two diameters 

upstream and eight diameters down stream from the nearest flow disturbances. Sampling 

was performed at 12 traverse points (6 per diameter). The ports are accessible from a 

platform approximately three feet above the main floor deck. 

Diagrams of the sampling location and traverse point locations are presented in Appendix 

C.1. 
Knauf Insulation, GmbH September 4, 2009 

2009 PM Emission Test 

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SECTION 3.0 

TEST DESCRIPTION

3.1 PROGRAM OBJECTIVES 

The objective of the program was to determine the compliance status of the source with 

respect to the facility’s operating permit conditions. The applicable standards are 

summarized in Table 3-1. 

TABLE 3-1 

PERMIT CONDITIONS 

KNAUF GMBH – GLASS FURNACE STACK 

Pollutants Applicable Standards 

Total Particulate Matter (PM) 

Emission Rate, lb/hr 1.0 

Emission Rate, tons/yr 4.4 

Emission Rate, lb/ton of glass pulled 0.5 

3.2 TEST CONDITIONS AND TEST PROGRAM SCHEDULE 

Testing was performed during normal process operating conditions established and 

maintained by Knauf personnel. Avogadro communicated with Knauf staff throughout 

the testing to ensure that representative operating conditions were maintained. Operating 

data were collected by Knauf during the test periods. These data are submitted under 

separate cover. 

All tests were performed on August 5, 2009. The test schedule is summarized in 

Table 3-2. 
Knauf Insulation, GmbH September 4, 2009 

2009 PM Emission Test 

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TABLE 3-2 

TEST SCHEDULE 

KNAUF GMBH – GLASS MELTING FURNACE 

Day Activity Test Runs Run Duration 

August 5, 2009 

Emission testing

PM (5/O28) 

PM (5/202) 

Vol. flow rate & moisture 

O2, CO2

1A, 2A, 3A 

1B, 2B, 3B 

w/PM 

1, 2, 3 

120 min. ea. 

120 min. ea. 

120 min. ea. 

120 min. ea. 

3.3 TEST PROCEDURES 

The test procedures used in this program are summarized in Table 3-3. Descriptions of 

standard procedures are included in Appendix A. Additional information on site-specific 

applications and any modifications to procedures are described in the following subsections. Where any conflicts exist in the descriptions, the specific description here in 

Section 3.3 will take precedence. 

TABLE 3-3 

TEST PROCEDURES 

KNAUF GMBH – GLASS MELTING FURNACE 

Parameter Measurement 

Principle 

Reference 

Method 

Method 

Detection Limit 

O2 Paramagnetism EPA 3A (modified) 2% of span 

CO2 Non-dispersive infrared EPA 3A (modified) 2% of span 

PM Gravimetry EPA 5/202 0.0005 gr/dscf 

EPA 5/OTM-028 0.0005 gr/dscf 

Moisture cont. Gravimetry EPA 4 -- 

Stack flow rate Pitot tube / temp. traverse EPA 1, 2 -- 
Knauf Insulation, GmbH September 4, 2009 

2009 PM Emission Test 

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3.3.1 Diluent Gases

Diluent gaseous emission tests (O2 and CO2) were performed concurrently with each 

particulate matter test. The 120-minute integrated samples were collected into Tedlar 

bags via an Orsat sampling system incorporated in the EPA Method 5 metering console. 

The samples were then introduced directly to the analyzers at the continuous emission 

monitoring system (CEMS) manifold in the same manner as the calibration error check 

procedure described below. 

Concentrations were measured using Avogadro’s dry extractive CEMS described in 

Appendix A. This system meets the requirements of EPA and CARB methods for 

gaseous species. 

The sample conditioning and delivery system includes components to extract a 

representative sample from the source, remove the moisture and particulate matter from 

the sample stream, and transport the sample to the analyzers. The primary components of 

this subsystem are: 

1) A quartz, titanium, stainless steel or glass probe - heated or insulated as 

necessary to avoid condensation, 

2) Sample filtration – filters located on the probe, pump, and prior to all of 

the analyzers for removal of particulate matter, 

3) Teflon tubing - connecting the probe to the sample conditioner and the 

sample conditioner to the analyzer manifold - heated or insulated as 

necessary to avoid condensation, 

4) Sample conditioner - glass or stainless steel flasks immersed in an ice bath 

to remove the moisture from the sample gas stream, 

5) Vacuum pump - a leak-free pump with Teflon diaphragm to transport the 

sample gas through the system, 

6) Sample manifold - a distribution system, constructed of stainless steel and 

Teflon tubing, to direct sample gas to the analyzers, and 

7) Sample flow rate control - a series of rotameters, vacuum gauges and 

pressure gauges connected to the manifold used to maintain the 

appropriate sample flow rates. 

The calibration gas system utilizes only EPA Protocol gases to verify the operation, 

linearity, and range settings of the electronic analyzers. The sample gas system allows 

for the introduction of the protocol gases to the analyzers either directly through the 

manifold (calibration error check - performed once daily) or through the sampling system 

(system bias check - performed with each run). 
Knauf Insulation, GmbH September 4, 2009 

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The electronic analyzers are rack-mounted and are maintained in the mobile lab. The 

data recording and acquisition system is based on a digital system known as STRATA. It 

includes software for controlling the collection of calibration and emission monitoring 

data, and hardware for connection of the analyzer outputs to the recording system. Test 

results can be provided in three forms: on-site printouts of the digitized data, diskette 

recordings of the digitized data, and printouts of strip charts from the monitoring data. 

3.3.2 Particulate Matter (5/202)

Emissions of total particulate matter (PM) were measured at the furnace stack according 

to EPA Methods 5 and 202. Three 120-minute test runs were conducted. The apparatus 

included a heated sampling probe, constructed of Pyrex, attached to an oven containing a 

heated glass filter holder and filter. The filter holder was connected by a length of Teflon 

tubing to the impinger train. The impinger train was connected to the control box, which 

contained the sampling pump and dry gas meter. The sampling rate and nozzle size were 

chosen to allow isokinetic sampling at the calculated rate. 

The filterable “front-half” PM was recovered from the sampling apparatus as described in 

the method. The samples included the probe and nozzle wash (water and acetone), filter, 

and rinses from the front-half of the filter holder (water and acetone). The samples were 

analyzed gravimetrically to determine the quantity of filterable PM collected. 

The condensable PM or “back-half” fraction of the PM was recovered and analyzed as 

described in EPA Method 202 including the optional post-test nitrogen purge. The 

impinger contents, the sample line, and the back-half of the filter holder were recovered 

with water rinses into a sample container. Each collected sample was extracted with 

dichloromethane in a separatory funnel, and the aqueous and organic fractions were 

separated for analysis. The analysis then included gravimetric measurement of the 

residue from the aqueous and organic fractions. The organic fraction was reduced to 

dryness at room temperature, and the aqueous fraction was dried at 105 degrees F for 

analysis of the residue weight. The results were added together to determine the 

concentration of condensable particulate matter. 

3.3.3 Particulate Matter (5/028)

Emissions of total particulate matter (PM) were measured at the furnace stack according 

to EPA Methods 5 and OTM 028. Three 120-minute test runs were conducted. The 

apparatus included a heated sampling probe, constructed of Pyrex, attached to an oven 

containing a heated glass filter holder and filter. The filter holder was connected by a 

heated length of Teflon tubing to the impinger train. The impinger train was connected to 

the control box, which contained the sampling pump and dry gas meter. The sampling 

rate and nozzle size were chosen to allow isokinetic sampling at the calculated rate. 
Knauf Insulation, GmbH September 4, 2009 

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The filterable “front-half” PM was recovered from the sampling apparatus as described in 

the method. The samples included the probe and nozzle wash (water and acetone), filter, 

and rinses from the front-half of the filter holder (water and acetone). The samples were 

analyzed gravimetrically to determine the quantity of filterable PM collected. 

The condensable PM or “back-half” fraction of the PM was recovered and analyzed as 

described in EPA Other Test Method (OTM) 028. The impinger contents, the sample 

line, and the back-half of the filter holder were recovered with water rinses into a sample 

container. This rinse procedure was then repeated with acetone followed by 

dichloromethane. These solvent rinses were collected into a separate sample container. 

Each collected aqueous sample was extracted with dichloromethane in a separatory 

funnel, and the aqueous and organic fractions were separated for analysis. The analysis 

then included gravimetric measurement of the residue from the aqueous and organic 

fractions. The results were added together to determine the concentration of condensable 

particulate matter. 

3.3.4 Volumetric Flow Rate and Moisture Content

Stack gas volumetric flow rates were determined according to EPA Methods 2 and 4. 

Velocity traverses were performed on the exhaust stacks using an S-type Pitot tube and a 

manometer. Velocity traverse data were collected as part of the particulate emission 

tests. Similarly, stack gas moisture data were collected in conjunction with the 

particulate sampling. The volumetric flow rate results were corrected to standard 

conditions and used with the concentration data to calculate mass emission rates. 
Knauf Insulation, GmbH September 4, 2009 

2009 PM Emission Test 

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SECTION 4.0 

DISCUSSION OF RESULTS

Particulate matter testing was performed using EPA Methods 5/202 and 5/ OTM 028 

concurrently. 

The test results for each method are summarized in Table 1-1. Results of the individual 

test runs are presented in Table 4-1. 

Referring to Tables 1-1 and 4-1, the particulate matter emissions test results for both 

Methods 5/202 and 5/028 are well below the applicable standards (AS) for the glass 

melting furnace stack for the average of all method specific test runs as well as for each 

individual test run. 

Additional information is included in the appendices. Appendix A contains descriptions 

of standard measurement procedures. Appendix B presents the quality assurance 

information, including instrument calibration data. Raw field data sheets are included in 

Appendix C. Appendix D presents the general and specific equations used for the 

emissions calculations and computer spreadsheets. Laboratory data are presented in 

Appendix E. The facility’s operating permits are presented in Appendix F. 
Knauf Insulation, GmbH 

2009 PM Emission Test 09090.6m, SCAQMD 10 

TABLE 4-1 

SUMMARY OF PARTICULATE MATTER TEST RESULTS 

KNAUF GMBH – GLASS MELTING FURNACE 

AUGUST 5, 2009 

Test No: 1-PM-202 1-PM-028 2-PM-202 2-PM-028 3-PM-202 3-PM-028 20

Date: 8/5/09 8/5/09 8/5/09 8/5/09 8/5/09 8/5/09 

Time: 0715-0921 0715-0921 1005-1208 1005-1209 1229-1431 1229-1431 O2, % volume dry: 20.73 20.73 20.71 20.71 20.69 20.69 

CO2, % volume dry: 0.426 0.426 0.422 0.422 0.512 0.512 

Stack gas temperature, oF: 133.7 133.0 143.4 143.1 150.9 151.5 Moisture content, % by vol. 2.05 2.00 2.07 2.04 2.29 2.20 Volumetric flow rate, acfm 24,857 26,240 25,383 25,907 25,086 25,541 Volumetric flow rate, dscfm 20,548 21,727 20,495 20,935 19,960 20,321 

F1⁄2 (filter), gr/dscf 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 F1⁄2 (acetone), gr/dscf 0.0004 0.0003 0.0001 0.0000 0.0000 0.0000 Total F1⁄2 grain loading, gr/dscf 0.0004 0.0003 0.0001 0.0000 0.0000 0.0000 F1⁄2 (filter), lb/hr 0.000 0.000 0.000 0.000 0.000 0.000 F1⁄2 (acetone), lb/hr 0.065 0.059 0.012 0.005 0.005 0.001 Total F1⁄2 mass emissions, lb/hr 0.065 0.059 0.012 0.005 0.005 0.001 B1⁄2 (aqueous), gr/dscf 0.0003 0.0004 0.0003 0.0003 0.0002 0.0003 B1⁄2 (organic), gr/dscf 0.0001 0.0002 0.0004 0.0005 0.0005 0.0003 Total B1⁄2 grain loading, gr/dscf 0.0004 0.0006 0.0008 0.0008 0.0007 0.0006 B1⁄2 (aqueous), lb/hr 0.059 0.069 0.061 0.057 0.043 0.050 B1⁄2 (organic), lb/hr 0.015 0.034 0.072 0.090 0.079 0.049 Total B1⁄2 mass emissions, lb/hr 0.074 0.103 0.133 0.147 0.122 0.099 
Knauf Insulation, GmbH 

2009 PM Emission Test 09090.6m, SCAQMD 11 

TABLE 4-1 (CONTINUED) 

SUMMARY OF PARTICULATE MATTER TEST RESULTS 

KNAUF GMBH – GLASS MELTING FURNACE 

AUGUST 5, 2009 

Test No: 1-PM-202 1-PM-028 2-PM-202 2-PM-028 3-PM-202 3-PM-028 20Date: 8/5/09 8/5/09 8/5/09 8/5/09 8/5/09 8/5/09 

Time: 0715-0921 0715-0921 1005-1208 1005-1209 1229-1431 1229-1431 O2, % volume dry: 20.73 20.73 20.71 20.71 20.69 20.69 

CO2, % volume dry: 0.426 0.426 0.422 0.422 0.512 0.512 

Stack gas temperature, oF: 133.7 133.0 143.4 143.1 150.9 151.5 Moisture content, % by vol. 2.05 2.00 2.07 2.04 2.29 2.20 Volumetric flow rate, acfm 24,857 26,240 25,383 25,907 25,086 25,541 Volumetric flow rate, dscfm 20,548 21,727 20,495 20,935 19,960 20,321 

Total grain loading, gr/dscf 0.0008 0.0009 0.0008 0.0008 0.0007 0.0006 Total mass emissions, lb/hr 0.138 0.162 0.145 0.152 0.127 0.100 Total mass emissions, tons/yr 0.606 0.710 0.635 0.667 0.555 0.439